The present disclosure relates to generating a modified gear flank geometry on an active surface of the workpiece by generation grinding or honing. In at least one example, the modified gear flank geometry of the workpiece may be generated on the active surface of the workpiece by variation of an engagement depth of a tool into the workpiece in dependence on an angle of rotation of the tool. Additionally, the workpiece may comprise a cylindrical spur gear, a helical gear, a spherical gear, or a conical gear. Further, in one or more examples, the modified gear flank geometry of the workpiece includes at least one of a profile waviness or a defined periodic flank waviness.

A method for automatic process monitoring during continuous generating grinding of pre-toothed workpieces, which permit early detection of grinding wheel breakouts. A generating grinding machine is used to machine multiple workpieces by clamping them onto at least one workpiece spindle and successively moving them into generating engagement with a grinding wheel. At least one measured variable is monitored during the machining to indicate if a grinding wheel breakout exists. If a grinding wheel breakout is indicated, the grinding wheel is examined automatically by moving a dressing tool over the tip region of the grinding wheel and generating a contact signal. A breakout is determined by analyzing the contact signal and, if present, the grinding wheel is dressed as often as necessary in order to eliminate the grinding wheel breakout. Alternatively, the checking of the grinding wheel is carried out directly at the first dressing stroke.

The presented disclosure provides a gear processing apparatus, including a base, a bearing unit, a grinding unit, and a control unit. The bearing unit and the grinding unit are arranged on the base. The bearing unit is configured to carry the gear. The grinding unit includes a driving module and a grinding member connecting to the driving module. The grinding member can perform a motion of a plurality of axial directions relative to the bearing unit to contact the tooth surface of the gear. The control unit is electrically connected to the bearing unit and the grinding unit. The control unit is configured to control the driving module to apply additional motion to at least one of the plurality of axial directions during the grinding process to drive the grinding member to grind the tooth surface of the gear.

Method for cutting a gear (4) from a metal workpiece (2), in which a tooth flank, still having an oversize compared with its predefined final geometry, of the gear is, in one or more cutting passes in cutting engagement with one or more cutting tools (10) fed thereto, hard-fine finished with a geometrically undefined cutting edge made of cutting grains incorporated in a binder matrix, in order to produce a reflective property, existing in the final geometry, of its surface, wherein, in a cutting pass of a cutting tool (10b), both an elastically resilient mounting of the cutting grains set by its binder matrix acts on this surface property, and a cutting reduction of the oversize by at least 2 μm at the tooth flank is realized by a compressive preload, set via the infeed of the cutting tool, to which the cutting engagement is subjected; as well as a gear-cutting tool and a machine tool for this purpose.

A tool which can be used for gear manufacturing machining of a workpiece may be dressed on a dressing machine, and the dressing may take place with line contact between the dresser and the tool. A specific modification of the surface geometry of the tool is produced by the suitable selection of the position of the dresser with respect to the tool during dressing. The specific modification of the surface geometry of the workpiece is specifiable with regard to various parameters.

The present disclosure relates to generating a modified gear flank geometry on an active surface of the workpiece by generation grinding or honing. In at least one example, the modified gear flank geometry of the workpiece may be generated on the active surface of the workpiece by variation of an engagement depth of a tool into the workpiece in dependence on an angle of rotation of the tool. Additionally, the workpiece may comprise a cylindrical spur gear, a helical gear, a spherical gear, or a conical gear. Further, in one or more examples, the modified gear flank geometry of the workpiece includes at least one of a profile waviness or a defined periodic flank waviness.

The present disclosure relates to a method for the manufacture of a workpiece having a corrected gear geometry and/or a modified surface structure, in particular by a hard finishing process, in particular generation grinding or honing. Provision is made in this respect that it is achieved by a direct generation of a wobble movement and/or of an eccentricity of the tool that a modification, in particular a profile modification or profile waviness, and/or a defined periodic flank waviness is generated on the active surface of the workpiece machined therewith.

Method for cutting a gear (4) from a metal workpiece (2), in which a tooth flank, still having an oversize compared with its predefined final geometry, of the gear is, in one or more cutting passes in cutting engagement with one or more cutting tools (10) fed thereto, hard-fine finished with a geometrically undefined cutting edge made of cutting grains incorporated in a binder matrix, in order to produce a reflective property, existing in the final geometry, of its surface, wherein, in a cutting pass of a cutting tool (10b), both an elastically resilient mounting of the cutting grains set by its binder matrix acts on this surface property, and a cutting reduction of the oversize by at least 2 m at the tooth flank is realized by a compressive preload, set via the infeed of the cutting tool, to which the cutting engagement is subjected; as well as a gear-cutting tool and a machine tool for this purpose.

A tool which can be used for gear manufacturing machining of a workpiece may be dressed on a dressing machine, and the dressing may take place with line contact between the dresser and the tool. A specific modification of the surface geometry of the tool is produced by the suitable selection of the position of the dresser with respect to the tool during dressing. The specific modification of the surface geometry of the workpiece is specifiable with regard to various parameters.