METHOD FOR MACHINING OF BALL TRACKS OF INNER RACES OF CONSTANT VELOCITY JOINTS

Abstract

A method for machining of ball tracks of an inner race of a constant velocity joint includes the step of providing a power skiving tool having a plurality of cutting members and a first axis of rotation and providing a work piece having an outer envelope surface extending along an axis of rotation. The first axis of rotation of the power skiving tool is arranged at a first distance from the axis of rotation of the work piece and oriented at a first angle. A first rotational speed to the power skiving tool and a second rotational speed to the work piece and a relative movement between the work piece and the power skiving tool, is applied such that the cutting members engage the outer envelope surface to machine the ball tracks. A cutting insert and a power skiving cutting tool are also provided.

Claims

1. A method for machining of ball tracks of an inner race of a constant velocity joint, said method comprising the steps of: providing a power skiving tool including a tool body and a plurality of cutting members arranged along a periphery of said tool body, each of said cutting members including a cutting edge, said power skiving tool further having a first axis of rotation; providing a work piece including an outer envelope surface extending along an axis of rotation of the work piece; arranging said power skiving tool and said work piece such that said first axis of rotation of said power skiving tool is arranged at a first distance from said axis of rotation of the work piece along a radial direction of said work piece perpendicular to said axis of rotation of the work piece and further such that said first and the work piece axis of rotation are oriented at a first angle relative to one another; applying a first rotation to said power skiving tool, said first rotation having a first rotational speed; applying a second rotation to said workpiece, said second rotation having a second rotational speed, wherein said first and second rotational speeds are synchronized; and applying a relative movement between said work piece and said power skiving tool along a direction parallel to said axis of rotation of said work piece, such that the cutting edges of said cutting members engage said outer envelope surface of said work piece by a combined relative translational and rotational movement to machine the ball tracks in said outer envelope surface along said axis of rotation of said work piece.

2. The method according to claim 1, further comprising machining the ball-tracks by multiple passes of the power skiving tool comprising the steps of: arranging said power skiving tool and said work piece such that said first axis of rotation of said power skiving tool is arranged at a second distance from said axis of rotation of said work piece along said radial direction of said work piece, wherein the second distance is smaller than said first distance; and applying at least one additional relative movement between said work piece and said power skiving tool along said direction parallel to said axis of rotation of said work piece, such that the cutting edges of said cutting members engage said ball tracks in said outer envelope surface of said work piece by a combined relative translational and rotational movement to machine a larger depth on the ball tracks in said radial direction of said workpiece.

3. The method according to claim 1, further comprising the steps of: providing a second power skiving cutting tool for machining internal splines of said inner race of the constant velocity joint, the second power skiving tool including a plurality of cutting members arranged along a periphery of said second power skiving tool, each of said cutting members including a cutting edge, the second power skiving tool having a second axis of rotation; arranging said second power skiving tool and said work piece such that said second axis of rotation of said second power skiving tool is arranged at a third distance from said axis of rotation of said work piece along the radial direction of said work piece, said axis of rotation of workpiece and second axis of rotation being oriented at a second angle relative one another; applying a third rotation to said second power skiving tool, said third rotation having a third rotational speed; applying a fourth rotation to said work piece, said fourth rotation having a fourth rotational speed, wherein said third and fourth rotational speeds are synchronized; and applying a relative movement between said work piece and said second power skiving tool along a direction parallel to said axis of rotation of said work piece, such that the cutting edges of said cutting members of the second power skiving tool engage an inner surface of said work piece by means of a combined relative translational and rotational movement to machine the internal splines in said inner surface along said axis of rotation of said work piece.

4. The method according to claim 1, further comprising the steps of: providing an additional power skiving cutting tool, said additional tool having a tool body and a plurality of cutting members arranged along a periphery of said tool body, each of said cutting members including a cutting edge and an axis of rotation; arranging said additional tool and said work piece such that a center point of said additional cutting tool is arranged at a first distance from a center point of said work piece along a radial direction of said work piece, perpendicular to said axis of rotation wherein said axis of rotation and said second axis of rotation are oriented at a third angle relative one another; applying a fifth rotation to said additional tool, said fifth rotation having a fifth rotational speed; applying a sixth rotation to the work piece, said sixth rotation having a sixth rotational speed, wherein said fifth and sixth rotational speeds are synchronized; and applying a relative movement between said work piece and said additional tool along a direction parallel to said axis of rotation of said work piece, such that the cutting members of said additional tool engage said outer surface of said work piece by a combined relative translational and rotational movement, thereby achieving a plurality of longitudinal tracks extending along said outer surface in a direction along said axis of rotation of said work piece.

5. The method according to claim 1, wherein at least one of said first, second and/or third angles lies in the range 20-45.

6. A cutting insert arranged to be replacably arranged along a periphery of a tool body of a power skiving cutting tool for machining of ball tracks of an inner race of a constant velocity joint, said cutting inserts comprising: a rake face; a lower face opposite to said rake face and arranged to abut an insert seat of the tool body; and a clearance surface extending between the rake face and the lower face, wherein a cutting edge is formed between said rake face and said clearance surface, substantially an entirety of the cutting edge being continuously curved defining an arc having a continuously varying radius with respect to a center point of said cutting insert, wherein said cutting insert has an insert width extension along a first axis and an insert length extension along a second axis, perpendicular to said first axis, and wherein said center point is positioned on the rake face at half the insert length extension and half the insert width extension.

7. The cutting insert according to claim 6, wherein the insert width extension is larger than the insert length extension.

8. The cutting insert according to claim 6, wherein at least one of said insert width extension and said insert length extension lies in the range of 8-50 mm.

9. The cutting insert according to claim 6. wherein the lower face comprises includes a plurality of grooves, a first groove extending along said second axis and a second groove extending along said first axis, wherein the first and second groove extend to form an intersection coinciding with the center point of the cutting insert.

10. The cutting insert according to claim 6, further comprising a screw hole located at the center point of the cutting insert.

11. The cutting insert according to claim 6, wherein said cutting insert is an indexable cutting insert having a 180 degree rotational symmetry.

12. A power skiving tool for machining of ball tracks of an inner race of a constant velocity joint, said power skiving tool comprising: a tool body; and a plurality of cutting members arranged along a periphery of said tool body, each of said plurality of cutting members including a rake face, a clearance surface, and a cutting edge formed between said rake face and said clearance surface, wherein said cutting edge is curved defining an arc having a continuously varying radius with respect to a center point of said cutting member, wherein said cutting member has a width extension along a first axis and a length extension along a second axis, perpendicular to said first axis, and said center point being positioned on the rake face at half the length extension and half the width extension of the cutting member.

13. The power skiving tool according to claim 12, wherein said plurality of cutting members are replaceable cutting inserts according to claim 6.

14. The power skiving tool according to claim 12, wherein each of said plurality of cutting members is arranged at an angle with respect to a reference plane perpendicular to the axis of rotation of the tool body, such that a plane defined by the rake face forms an angle with the reference plane, wherein the angle is in the range of 20-55

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The invention will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments, with reference to the appended drawing, on which:

[0057] FIG. 1 is a perspective view of a cutting tool according to one embodiment and a work piece;

[0058] FIG. 2 is a bottom view of a cutting tool according to one embodiment, particularly the insert seat and inserts;

[0059] FIG. 3 is a side view of a cutting tool according to one embodiment;

[0060] FIGS. 4a-f are different views of a cutting insert according to one embodiment;

[0061] FIG. 5 is a view from below showing a cutting tool according to one embodiment and a work piece during an exemplary stage of machining;

[0062] FIG. 6 is a side view showing a cutting tool according to one embodiment and a work piece during an exemplary stage of machining;

[0063] FIGS. 7a and b are cross sectional views of two exemplary ball tracks achievable by means of the disclosed method;

[0064] FIG. 8 shows an inner race with helix ball tracks machined by means of the disclosed method.

[0065] All figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the invention, wherein other parts may be omitted or merely suggested.

DETAILED DESCRIPTION OF EMBODIMENTS

[0066] A power skiving tool 1 according to one exemplary embodiment is shown in a perspective view along with an exemplary workpiece 2. The tool 1 comprises a tool body 10 which may be described as ring, or disc-shaped, extending along an axial direction A, coinciding with the axis of rotation R.sub.t1 of the tool, and along a radial direction R. A plurality of cutting members in the form of replaceable inserts 100 are arranged equally spaced along a periphery P of the tool body.

[0067] The illustrated tool body 10 is a steel body and is adapted to be attached the tool to a spindle providing a rotational movement to the tool, by means of an engagement by means of the center hole H.

[0068] The outer diameter of the tool body of the illustrated embodiment, i.e. the diameter at the periphery of the tool body, is approximately 150 mm. Further, the illustrated exemplary embodiment of FIG. 1 comprises twelve cutting inserts 100 arranged along the periphery of the tool body, the design of which will be descried in greater detail in the following. The tool body 10 therefore includes twelve insert seats 11 arranged equally spaced along the periphery, shown in more detail in FIG. 2. The cutting members are removably, or replaceably, attached to the insert seats 11, in the illustrated case by means of screws (not shown).

[0069] As shown in FIG. 2, in the illustrated embodiment the insert seats 11 therefore each comprise a hole 11a, adapted to axially coincide with a center hole of the insert (not shown in FIG. 2) such that the screw mentioned above may be inserted through both holes in order to attach the insert to the tool body. The bottom surface of the insert seat of the illustrated embodiment further comprises two sets of grooves and ridges 11b, 11c; 11b, 11c extending perpendicularly with respect to one another and adapted to mate with corresponding grooves provided on the lower side of the insert in order to provide stability to the engagement between the insert and the seat 11.

[0070] Further, turning to FIG. 3 showing a side view of the insert and the work piece, in the illustrated embodiment each of the insert seats 11 are designed such that the cutting inserts are arranged having an inclination with respect to a reference plane P.sub.r, as shown in FIG. 3 perpendicular to the axis of rotation of the tool body, such that a plane defined by the insert, more particularly the rake face of the insert forms an angle with the reference plane P.sub.r, in the illustrated embodiment the angle is 50.

[0071] Turning to FIGS. 4a-f, the design of an exemplary cutting insert according to an embodiment of the present specification will be described in detail.

[0072] FIGS. 4a and b show an upper and lower view of such a cutting insert 100. The cutting insert 100 comprises an upper face 110, i.e. a rake face 110 and a lower face 120, opposite and parallel to the rake face 110. A clearance surface 130 is formed between the rake face 110 and the lower face 120. A cutting edge 140 is formed between the rake face 110 and the clearance surface 130. Further, a through hole 150 (i.e. a screw hole 150) extends between the upper/rake and lower face 110, 120.

[0073] The general shape, or profile, of the insert 100, more particularly of the rake face 110 and the cutting edge 140 is illustrated in FIG. 4c, a side view of the insert showing the upper, or rake face 110. FIG. 4c further illustrates an asymmetric design feature of the insert, wherein the length of a first side portion 112 is larger than the length of a second side portion 113. A rear portion 111 of the cutting insert is adapted to face the axis of rotation of the tool body when the cutting insert is mounted in the power skiving tool.

[0074] Further, the cutting insert 100 has an insert width extension along a first axis A1 and an insert length extension along a second axis A2, perpendicular to said first axis A1. The cutting edge 140 is continuously curved describing an arc having a continuously varying radius R with respect to a predetermined point P, in the illustrated case a center point P positioned on the rake face 110 at half the insert length extension and half the insert width extension. In FIG. 4c this center point P coincides with a center point of the through hole 150.

[0075] In the embodiment illustrated in FIG. 4c, a center line CL extends between a front and a rear side FS, RS of the rake face. The rear side RS is a side of the insert is located closer to the rotational axis of the tool body, i.e. an opposite side compare to the front side FS of the rake face along which the cutting edge is extending. Further, the rear portion 111 of the insert along the rear side RS of the rake face also forms a flat rear surface, which extends substantially perpendicular to the rake face. Further, as may be seen in FIG. 4c, the direction of extension of the first axis A1 is in the illustrated embodiment parallel to the extension of the flat rear surface/portion 111 extending between the rake face 110 and the lower face 120. Similarly, the first side portion 112 mentioned above forms a flat side surface and the direction of extension of the second axis A2 of the insert is in the illustrated embodiment parallel to the direction of the first portion or flat side surface 112 extending between the rake face 110 and the lower face 120.

[0076] Further, with regards to what may be referred to as the general shape of the insert 100 the insert width extension is larger than the insert length extension. Accordingly, the insert has a continuously curved outer contour along the cutting edge, by outer should be understood the front side of the insert facing away from the rotational axis of the power skiving tool.

[0077] In the illustrated embodiment, the insert width extension is approximately 25 mm, whereas the insert length extension is approximately 16 mm. The exact dimensions of the insert 100 is however dependent on the application and the size of the balls of the constant velocity joint to be manufactured.

[0078] Turning to FIG. 4d, the lower side 120 of the insert 100 is shown in detail. In the illustrated embodiment, the lower face 120 comprises a plurality of grooves and ridges, wherein a first groove 121, or first subset of grooves and ridges, extend along the first direction and a second groove 122, or second subset of grooves, extend along the second direction. As described above with reference to the insert seat 11 of the tool body 10, such grooves are adapted to mate with corresponding structures provided on the insert seat, thereby providing improved stability to the engagement between the insert and the seat.

[0079] FIGS. 4e and 4f are side views of the insert 100 showing the clearance surface 130, including the angle which in the illustrated case amounts to approximately 110 and the right angle (i.e. 90 degrees angle) at the first and second portion 112, 113.

[0080] Returning again to FIG. 1, the inventive method for machining of inner races of ball tracks for constant velocity joints will now be described in greater detail.

[0081] According to one embodiment of the method a power skiving cutting tool, such as the tool 1 illustrated in FIG. 1 is provided, the tool comprising a tool body 10 and a plurality of cutting members 100 arranged along the periphery of said tool body and further has an axis of rotation R.sub.t1, as indicated in FIG. 1. Further, a work piece 20 is provided, the workpiece comprises an outer envelope surface 21 extending along an axis of rotation R.sub.wp of the work piece.

[0082] As illustrated in FIG. 5, the tool 1 and the work piece 20 are then to be arranged such that said axis of rotation of said cutting tool is arranged at a first distance D1 from said axis of rotation work piece along a radial direction of said work piece perpendicular to said axis of rotation R.sub.wp and further such that said first and second axis of rotation are oriented at an angle relative one another. The angle , i.e. the angle setting of the work piece versus the axis A of the rotational tool is in the illustrated embodiment equal to 45, shown in FIG. 6.

[0083] Further, a first rotation (i.e. a rotational movement) is applied to the tool 1, the first rotation having a first rotational speed and a second rotation is applied to the work piece 20, having a second rotational speed. The first and second rotational speeds are synchronized, more particularly synchronized by a suitable ratio.

[0084] A relative movement is then applied between the work piece 20 and the tool 1 along a direction parallel to the axis of rotation of the work piece 20, such that the cutting inserts 100 of the tool 1 engage the outer surface 21 of the work piece 20 by means of a combined relative translational and rotational movement, thereby achieving a plurality of tracks 22, i.e. inner races or tracks, extending along the envelope surface 21 along the axis of rotation R.sub.wp of the work piece 20.

[0085] Accordingly, the power skiving tool 1 is designed for machining of ball tracks or inner races 22 by a synchronized rotation and relative axial movement between the work piece 20 and the power skiving tool 1, to thereby machine the inner races of ball tracks 22 faster and more efficient than the known prior art.

[0086] Two types of ball tracks 22 achievable by means of the described method are shown in cross section in FIGS. 7a and 7b, wherein FIG. 7a shows a so called radius profile and FIG. 7b shows a so called elliptic profile or geometry. The cross section of the radius ball track of FIG. 7a accordingly has a radius adapted to the ball radius r, and any tolerances associated, whereas the cross section of the elliptic geometry of FIG. 7b may be described by means of the relationship between the ball diameter D.sub.K, the ball radius r and the contact points A and B.

[0087] The work piece 20 illustrated in FIGS. 1, 5 and 6 constitutes an inner housing of a constant velocity joint and is shown at a stage of machining, and accordingly exhibiting a plurality of inner races 22 having an intermediate depth somewhat smaller than a desired final depth of cut and possibly also a non-finished surface finish extending along the outer envelope surface 21 as well as a plurality of internal splines 24 extending along an inner surface 23.

[0088] In order to achieve the final desired depth and possibly finish, the method may within the scope of the present application, further comprise additional steps. For example, the step of subsequently, i.e. following the first relative movement described above, arranging the power skiving tool and the work piece such that the axis of rotation of the power skiving tool is arranged at a second distance D2, exemplary illustrated in FIG. 5, from the axis of rotation work piece along the radial direction of the work piece. As shown in FIG. 5 D2<D1, hereby by, by means of applying an additional relative movement between the work piece and the tool along a direction parallel to the axis of rotation of the work piece, such that the cutting edges of the power skiving tool now engage the tracks 22 of the work piece by means of a combined translational and rotational movement at a larger depth in the radial direction of the tracks. This step may be repeated until a desired depth of the ball tracks is achieved.

[0089] Further, an additional step of so called finishing power skiving may be utilized in order to achieve a desired surface quality. In such a case the method is commonly performed using a specifically adapted embodiment of the power skiving tool according to the present specification, performing a single pass operation over the ball tracks according to what has been described for the method above.

[0090] The inner splines 24 on the inner surface 23 may be provided by means of an additional method step for example following, or preceding, the machining of the ball tracks, wherein a second power skiving cutting tool for machining internal splines of constant velocity joints is provided and a relative movement between the work piece and the second tool is applied along a direction parallel to the axis of rotation of the work piece, such that the cutting members of the second cutting tool engage the inner surface 23 of the work piece by means of a combined relative translational and rotational movement, thereby achieving the plurality of internal longitudinal splines 24 shown for example in FIGS. 1 and 3.

[0091] A second exemplary work piece 20 is illustrated in FIG. 8. This workpiece may constitute an inner housing of a specific type of constant velocity joint known in the art as VL-type joints, and differs from the work piece shown for example in FIG. 1 in that it comprises inner races having two helical dimensions. More particularly, the work piece of FIG. 8 has a number of right hand helix ball tracks 22 and a number of left hand helix ball tracks 22. Such a helix may be inclined for example 11, 14 or 16.

[0092] Depending on the application, such helix shaped ball track inner races may be achieved by means of the method steps described in the foregoing, albeit using a first and a second power skiving tool, normally a right hand tool and a left hand tool. Accordingly, in such a case, the right hand helix ball track inner races may be achieved by means of a first relative movement between the work piece and the first power skiving tool along a direction parallel to the axis of rotation of the work piece, such that the cutting edges of the cutting members engage the outer envelope surface of said work piece by means of a combined relative translational and rotational movement whereas the left hand ball track inner races may be achieved by means of a second relative movement between the work piece and the second power skiving tool along a direction parallel to the axis of rotation of the work piece, such that the cutting edges of the cutting members engage the outer envelope surface of said work piece by means of a second combined relative translational and rotational movement. The skilled eprson realizes that the direction of rotation of the workpiece may be suitably adapted to the direction of rotation of the resepctive power skiving tool.

[0093] However, in some cases a single tool may be used as well. Such a single tool is preferably designed such that adjacent seats (i.e. adjacent cutting members are tilted in opposite directions.

[0094] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. The skilled person understands that many modifications, variations and alterations are conceivable within the scope as defined in the appended claims.

[0095] Additionally, variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word comprising does not exclude other elements or steps, and the indefinite article a or an does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope of the claims.