The invention concerns a method for producing tooth flank modifications on toothings of workpieces according to the preamble of claim 1 as well as at least one tool for performing the method according to claim 9.
In the course of electromobility, increased importance is placed on the noise behavior of gear mechanisms. The tonal characteristic of the gear noise is perceived as particularly disturbing. Tonal noises are characterized in that the frequency spectrum comprises pronounced amplitudes of individual frequencies (tones) that lie above the amplitude level of the basic noise. In gear toothings, these are in particular, but not exclusively, the frequency of the tooth engagement and its higher harmonic that determine substantially the tonality of the gear noise. With increasing rotational speed, often the tonality increases. In order to reduce the gear noise, flank modifications that are of great importance for the running behavior are carried out at the toothings of the gear wheels. Usually, the modifications are identically provided tooth by tooth. By a variable flank modification tooth by tooth, a significant improvement of the running behavior and thus also of the noise behavior is observed because in particular the tonality, produced by an identical excitation of tooth engagement to tooth engagement, is reduced.
In order to provide such flank modifications at the teeth, usually the discontinuous profile grinding is employed. For this purpose, the position of the tool in regard to the engagement conditions at the workpiece is somewhat changed space by space. Such methods are however very complex and only little suitable for a highly productive manufacture.
For highly productive manufacturing methods, continuously rolling manufacturing methods are employed. However, only the same flank modification can always be provided by them at the teeth of the workpiece. However, the tonality and thus the noise behavior can be reduced only minimally in this way.
The invention has the object to design the method of the aforementioned kind and the tools in such a way that in an inexpensive and in a highly productive manner the noise development of a gear mechanism can be significantly reduced.
This object is solved for the method of the aforementioned kind in accordance with the invention with the characterizing features of claim 1 and for the tools in accordance with the invention with the features of claim 9.
With the method according to the invention, different tooth flank modifications at the workpiece can be produced tooth by tooth by a continuously rolling manufacturing method. For this purpose, the employed tool is provided with individually different tool profile geometries. In case of dressable tools, this geometry is introduced by a corresponding dresser with variable profile. During the rolling process, the different tooth flank modifications are produced at the teeth of the workpiece tooth by tooth with these different tool profile geometries. Depending on the configuration of the gear, the tool profile geometries at the tool are designed such that the tooth flank modifications at the workpiece formed by them lead to only a minimal noise development and in particular tonality of the gear. Due to the continuously rolling manufacturing manner the workpieces can be provided inexpensively and at high productivity.
For the continuously rolling manufacturing methods, the conventional known methods are conceivable, for example, a continuous generation grinding, continuous profile grinding, gear hobbing, gear honing, gear shaving, power skiving, gear shaping and the like. With these methods, the fine machining is possible in the soft as well as hardened workpiece material state.
Advantageously, a divider equality of number of teeth of the workpiece and number of teeth of the tool is realized.
As tools, worm-type embodied tools can be employed. They are used, for example, for continuous generation grinding, continuous profile grinding, gear hobbing and the like.
The worm-type tool can be provided with at least two threads that are differently profiled. In this manner, it is achieved that the individual tool profile geometries are periodically imprinted thread by thread on the workpiece to be machined.
The number of threads of the worm-type tool can be designed depending on the gear configuration and/or the workpiece to be machined. When the worm-type tool, for example, has three differently profiled threads, then the teeth of the workpiece are provided periodically with the corresponding tooth flank modifications. In case of three threads with different profiling, the formation of the tooth flank modifications is therefore repeated at the workpiece after three teeth, respectively.
In another advantageous embodiment, the worm-type tool is designed such that it comprises at least only one thread that along its length comprises differently profiled thread regions. These thread regions are then provided such that sequential teeth of the workpiece can be machined by them. In this case and also taking into account a targeted influence of the machining kinematics, it is not required that an integer divider is realized between the number of teeth of the workpiece and the number of threads of the tool.
The thread comprises at least two differently profiled thread regions so that at the workpiece two different tooth flank modifications can be provided. The different profiled thread regions are advantageously provided within the thread such that sequential teeth of the workpiece are provided with the respective tooth flank modification. Due to the continuously rolling manufacturing method, in the individual thread of the worm-type tool the corresponding thread regions are therefore arranged one behind the other so as to repeat at a distance. For imprinting different modifications, possibly a relative movement of the workpiece, e.g., by shifting (diagonal grinding) or a relative movement of the tool, e.g., by releasing the coupling of rolling is required.
The method is designed such that the workpiece that is installed later on in the gear can be machined directly with the tool. As tool, also a correspondingly geometrically modified dressing tool, e.g., multi-fluted profile rolls, can be employed with which the actual machining tool can be machined with respect to variable geometries. With the dressing tool, the different tooth flank modifications at the machining tool can be produced in a simple manner.
It is also possible to employ as machining tools gear wheel-type tools whose teeth are provided with different tooth geometries. They are employed, for example, for gear honing, gear shaping, power skiving, and the like. These different tooth geometries are periodically imprinted during the continuous rolling manufacturing method at the tooth flanks of the workpiece. The gear wheel-type tool has at least two different tooth geometries that advantageously are repeated irregularly about the circumference of the gear wheel-type tool.
The tool according to the invention for performing the method is characterized in that is comprises individual tool profile geometries. Depending on the number of these different tool profile geometries, at the workpiece corresponding tooth flank modifications can be provided. The tool has at least two individual tool profile geometries so that the workpiece to be machined can be provided with two different tooth flank modifications.
In an advantageous embodiment, the tool is embodied of a worm-type configuration. It can have in this context two threads that are differently profiled. With such a tool, the desired tooth flank modifications can be produced periodically at the workpiece.
In another advantageous embodiment, the tool is also of a worm-type configuration but provided with only one thread. In this case, the thread comprises along its length differently profiled thread regions. They are provided one after another at such a distance along the thread that the tooth flanks of sequential teeth of the workpiece can be modified with these thread regions.
Also, it is possible to design the tool like a gear wheel. In this case, the teeth are provided with an individual tooth geometry. This tool has then at least two individually different tooth geometries so that at the teeth of the workpiece at least two different tooth flank modifications can be provided. In this context, an integer divider ratio of the number of teeth of tool and workpiece is used.
The gear wheel-type tool can comprise an outer toothing or an inner toothing.
The tool can also be a dresser with variable profile in order to provide individually different tool profile geometries in case of dressable tools.
The subject matter of the application results not only from the subject matter of the individual claims but also from all specifications and features disclosed in the drawings and the description. They are considered important to the invention, even if they are not subject matter of the claims, inasmuch as, individually or in combination, they are novel in relation to the prior art.
Further features of the invention result from the additional claims, the description, and the drawings.
The invention will be explained in more detail with the aid of embodiments illustrated in the drawings. It is shown in
With the method disclosed in the following, individual teeth or threads of a tool are configured individually differently. For divider equality to the workpiece to be machined, these individual tooth geometries or thread geometries are applied onto the workpiece in a continuous method.
In case of no divider equality, in particular for worm-based tools, a variable tool geometry generation is realized not only per thread but also along the thread. Due to the coupling of the variable geometries thread by thread as well as along a thread with a corresponding feed kinematics, a flank-individual geometry is imprinted on the teeth of the workpiece.
In
In
The tooth flank modification according to
A further typical tooth flank modification is illustrated in
The end relief be, le in
In the production of the width crowning cβ (
Finally, the root relief cf is illustrated in
The tooth flank modifications illustrated with the aid of
The tooth flank modifications at the teeth of the gear wheel illustrated in
With this method, it is possible to satisfy the increasing requirements in regard to the noise behavior of gear wheels in particular in the field of electromobility. Since in the field of electromobility no noise-emitting combustion engines are present anymore, the noise behavior of the gear wheels or of the gear mechanism plays an important role. The tonality of the tooth engagement in the gears comes to the fore in electromobility. The tonality is broken due to the tooth-by-tooth variable geometries. These variable geometries can be produced by means of a continuously working method so that a high productivity is achieved.
The method can be a machining method or a dressing method.
The teeth can be components of gear wheels but also of dressing tools and machining tools for producing such gear wheels.
With the aid of
Alternatively, gear wheel-type tools can be employed. They are used, for example, in gear honing, gear shaving, (hard) power skiving or (hard) gear shaping.
With the aid of
The workpiece 9 has the number of teeth z2 which amounts to 12 in the embodiment.
The tool 10/11 has the number of threads z0 wherein in the embodiment three threads are individually profiled. These differently profiled threads are identified in
The number of teeth z2 of the workpiece 9 results thus from the equation
z
2
=n·z
0
herein with the meaning n=1, 2, 3, . . . .
Thus, the equation
z
2=12=4·z0
applies in the illustrated embodiment.
The tool 10 is a grinding tool that is embodied of a worm-type configuration and advantageously is dressable.
The tool 10 is in engagement with the workpiece 9 during machining. The workpiece 9 in the form of a spur gear rotates at the rotational speed n2 about its axis 13 which, in the usual manner, is positioned at an angle to the axis of rotation 12 of the workpiece 9.
The rotation of workpiece 9 and workpiece 10 is coupled kinematically in a known manner, wherein in addition the tool 10 is moved by a feed amount ae axially (axial feed fa) as well as advantageously tangentially in relation to the workpiece 9 in advancing direction. By means of the three individually profiled threads z0.1 to z0.3 of the tool 10, the corresponding tooth flanks of the workpiece 9 are profiled. Since the tool 10 comprises three differently profiled threads, corresponding differently modified tooth flanks can be produced at the teeth Z1 to Z12 by generation grinding.
As can be seen in
When a gear hobbing tool that is of a worm-type configuration is used as a tool 11, in principle the same sequences as for use of the generation grinding cylinder 10 result. The workpiece 9 and the tool 11 are rotated about their respective axes 12, 13 at the rotational speeds n2 and n0. In a known manner, the two axes of rotation 12, 13 are positioned at an angle relative to each other. The rotation of workpiece 9 and tool 11 is coupled again kinematically so that the desired profile can be produced at the workpiece 9 by the tool 11.
The tool 11 in the form of the gear hobbing tool has, for example, three individually profiled threads z0.1 to z0.3. Correspondingly, teeth comprising individually profiled tooth flanks, respectively, are produced at the workpiece 9 upon machining, as has been explained with the aid of the generation grinding method.
The two methods explained in an exemplary fashion by means of worm-type tool 10, 11 enable in a continuously working method the production of variable topographies tooth by tooth at the workpiece 9. In deviation from the embodiment, the tool 10, 11 can also be provided with only two individually profiled threads but also more than three individually profiled threads so that at the workpiece 9 a corresponding number of teeth with individually designed tooth flank modifications can be produced.
The tools 14, 15 have the tooth number z0 with an individual tooth geometry. The correlation of the respective tool 14, 15 to the workpiece 9 is realized in the same manner as in the embodiments according to
The workpiece 14 is a cylindrical honing stone with inner toothing. In workpiece machining, the tool 14 is rotated about the axis 13 and the workpiece 9 about the axis 12 at the rotational speeds n0 and n2. The two axes of rotation 12, 13 are positioned at an axis crossing angle Σ relative to each other. The rotational speeds n0 and n2 are matched to each other in a known manner.
The workpiece 9 is displaced during machining at an oscillation speed vosc in the direction of its axis 12 as well as perpendicularly thereto in accordance with the feed ae in the direction toward the tool 14. The gear honing is generally known and is therefore not explained here in more detail. The process applies in the same manner to workpieces with inner toothing as well as workpieces with outer toothing.
The workpiece 9 has the number of teeth z2, wherein the correlation with the number of teeth z0 of the tool 14 according to the equation z0=i·z2 applies, wherein i=1, 2, 3, . . . . This applies to a workpieces with outer toothing as illustrated in the embodiment.
When the workpiece has an inner toothing, then for the correlation between the number of teeth z2 of the workpiece 9 and the number of teeth of the tool 15 the relation z2=i·z0 applies wherein i=1, 2, 3, . . . .
The tool 14 comprises teeth with different profiling so that the teeth of the workpiece 9 in the described manner can be provided with different tooth flank modifications, depending on the configuration of the teeth z0 of the tool 14.
The rotations of workpiece 9 and tool 15 are coupled with each other in a known manner kinematically so that the tooth profile is produced in the desired degree. Due to the individual tooth geometries of the tool 15, teeth with individual flank modification can be produced at the workpiece 9 in a continuous method.
In an exemplary fashion, the employed tool 16 is a worm-type grinding tool with which a diagonal generation grinding can be performed. In this method, an axial advance and tangential advance occur simultaneously with the rotation of the tool 16 about its axis 13.
The tool 16 has in an exemplary fashion the number of threads Z0=1. This thread along its length is provided with differently profiled thread regions, as is illustrated in an exemplary fashion. The thread region Z0.1, Ref forms a reference region with which a reference tooth flank modification is produced at the tooth of the workpiece.
The thread region Z0.1 is designed such that with it, in the disclosed manner, a profile angle modification fHα at the tooth flank of the workpiece tooth can be produced.
The thread region z0.1,fHα,2 is designed such that with it a further different profile angle modification at the tooth flank 3 of the workpiece tooth can be produced.
The thread region z0.1,cα is formed such that with it at the tooth flank 13 of the workpiece 9 the profile crowning cα can be produced.
The thread regions are positioned at such a distance one behind the other that each thread region machines the tooth flanks of different teeth of the workpiece.
In
For diagonal generation grinding, the workpiece 9 and the tool 16 are rotated in a synchronized manner about their respective axes 12, 13 at rotational speeds n0, n2, wherein the two axes of rotation 12, 13, in a known manner, are arranged at a pivot angle relative to each other.
As can be taken furthermore from
For the coupling of rolling solution, it can be provided that the ratio of rotational speed n0 of the tool 16 to the rotational speed n2 of the workpiece 9 is not constant.
The pivot angle variation and the coupling of rolling variation are simply further examples as to how in a targeted fashion workpiece tooth flank modifications in a continuously rolling manufacturing method can be advantageously produced by affecting the method kinematics.
In the embodiment according to
As shown with the aid of the examples of
When non-dressable tools are used for the worm-type tools 10, 11, 16, then the variable tool geometries along a thread are ground in different thread regions, as explained in an exemplary fashion with the aid of
When realizing integer dividers between the number of teeth z2 of the workpiece and the number of teeth z0 of the tool, the same teeth of the workpiece 9 will always come into contact with the same thread of the tool 10, 11.
The result is that different thread geometries are imprinted onto the toothing of the workpiece 9 as variable geometries.
The use of the worm-type tool is in particular provided for finish gear hobbing, for generation grinding or for skiving gear hobbing.
When gear wheel-type tools are used as tools (
In this way, the different dresser tooth geometries are imprinted onto the toothing as variable geometries by the tools 14, 15. In an exemplary fashion, the gear honing process is explained for this purpose.
With the aid of
For this purpose, an integer divider between the number of teeth z2 of the workpiece 9 and the number of teeth z0 of the tool 15 is also realized so that always the same teeth of the workpiece 9 will come into contact with the same teeth of the tool 15.
Aside from skiving, for this purpose also shaving or in an exemplary fashion shaping are conceivable.
Due to the described divider equality of numbers of teeth of the workpiece and number of threads or number of teeth of the tool, in the described manner individual tool profile geometries are periodically imparted thread by thread or tooth by tooth onto the workpiece.
When during machining a targeted tool movement during the machining process is additionally performed, as explained in an exemplary fashion with the aid of
In addition, or in place of the targeted supplemental tool movement, a variable geometry along a thread or periodically engaging tool teeth can also be used as well as the manufacturing kinematics can be expanded as described in order to reinforce an individual geometry on the workpiece tooth by tooth. In this way, elimination of the divider equality of number of teeth of the tool or number of threads of the tool and number of teeth of the workpiece is possible.
With the described method, machining methods and dressing methods can be performed. For this purpose, the described machining tools 10, 11, 14 to 16 as well as corresponding dressing tools are employed.
Number | Date | Country | Kind |
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10 2019 004 667.0 | Jul 2019 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2020/000123 | 6/30/2020 | WO |