METHOD FOR MACHINING AND MEASURING WORKPIECES
20220379395 · 2022-12-01
Inventors
Cpc classification
G05B19/401
PHYSICS
G05B19/404
PHYSICS
B23F1/023
PERFORMING OPERATIONS; TRANSPORTING
B23F9/08
PERFORMING OPERATIONS; TRANSPORTING
B23F23/10
PERFORMING OPERATIONS; TRANSPORTING
B23F23/1218
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23F23/12
PERFORMING OPERATIONS; TRANSPORTING
B23F23/10
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for machining and measuring workpieces includes: machining a workpiece by a gear cutting process, wherein a tooth flank of the workpiece is produced or machined; measuring an actual geometry of the tooth flank produced by the gear cutting process by a measuring process; determining a deviation of the actual geometry from a predetermined nominal geometry of the tooth flank; determining a corrected gear cutting process for at least partially reducing the deviation; and machining the workpiece and/or a further workpiece by the corrected gear cutting process. The determination of the corrected gear cutting process for at least partial reduction of the deviation has the specification that a distinction is made between first and second evaluation areas of the tooth flank, wherein first and second permissible deviations of the actual geometry from the nominal geometry is specified for the evaluation areas of the tooth flank, respectively.
Claims
1. A method for machining and measuring workpieces, the method includes the following steps: machining a workpiece by a gear cutting process, wherein a tooth flank of the workpiece is produced or machined, measuring an actual geometry of the tooth flank of the workpiece generated by the gear cutting process using a measuring method, determining a deviation of the actual geometry of the tooth flank from a specified nominal geometry of the tooth flank, determining a corrected gear cutting process to at least partially reduce the deviation, and machining the workpiece and/or another workpiece by the corrected gear cutting process, wherein the determination of the corrected gear cutting process for at least partial reduction of the deviation has the specification that a distinction is made between a first evaluation area of the tooth flank and a second evaluation area of the tooth flank, wherein a first permissible deviation of the actual geometry from the nominal geometry is predetermined for the first evaluation area of the tooth flank, a second permissible deviation of the actual geometry from the nominal geometry is predetermined for the second evaluation area of the tooth flank, and the first permissible deviation is smaller than the second permissible deviation, and/or wherein for mathematical optimization for at least partial reduction of the deviation, a first weighting is specified for a deviation of the first evaluation area of the tooth flank and a second weighting is specified for a deviation of the second evaluation area of the tooth flank, wherein the first weighting is greater than the second weighting.
2. The method according to claim 1, wherein the first evaluation area has one or more sections of the tooth flank, which are arranged contiguously and/or at least in regions spaced apart from one another, and/or the second evaluation area has one or more sections of the tooth flank, which are arranged contiguously and/or at least in regions spaced apart from one another.
3. The method according to claim 1, wherein the first evaluation area is assigned a load-bearing area of the tooth flank which is at a distance from ends or edges of the tooth flank and/or the second evaluation area is assigned an edge region which has ends or edges of the tooth flank or is adjacent thereto.
4. The method according to claim 1, wherein the first evaluation area is assigned one or more sections of the tooth flank which, in operation, have a contact with a mating flank; and/or the first evaluation area is assigned one or more sections of the tooth flank for which a predetermined load threshold or a predetermined load criterion is exceeded during operation; and/or the second evaluation area is assigned one or more sections of the tooth flank which have no contact with a mating flank during operation; and/or the second evaluation area is assigned one or more sections of the tooth flank for which the load falls below a predetermined load threshold or a predetermined load criterion during operation.
5. The method according to claim 1, wherein when the actual geometry of the tooth flank of the workpiece generated by the gear cutting process is measured by the measuring process, a measuring grid with measuring points is detected, when determining the deviation of the actual geometry of the tooth flank from the predetermined nominal geometry of the tooth flank, a respective deviation of the actual position of the respective measuring point from the nominal position of the respective measuring point is determined for each measuring point of the measuring grid, and a first group of the measuring points is assigned to the first evaluation area, and a second group of the measuring points is assigned to the second evaluation area.
6. The method according to claim 1, wherein, after machining of the workpiece and/or of a further workpiece by the corrected gear cutting process, an actual deviation of a tooth flank machined by the corrected gear cutting process is smaller for the first evaluation area than the first permissible deviation and is smaller for the second evaluation area than the second permissible deviation.
7. The method according to claim 1, wherein two or more tooth flanks of the workpiece are produced or machined during machining of the workpiece by the gear cutting process, when measuring the actual geometry generated by the gear cutting process, two or more tooth flanks of the workpiece are measured by the measuring method; when determining deviations of the actual geometry of the respectively measured tooth flanks from the predetermined nominal geometry, an average deviation is determined from the deviations of the respectively measured tooth flanks; and the corrected gear cutting process for at least partial reduction of the deviations is determined on the basis of the mean deviation and applies to all tooth flanks.
8. The method according to claim 1, wherein the corrected gear cutting process has modified process kinematics compared to the gear cutting process, and/or the corrected gear cutting process has a modified tool geometry compared to the gear cutting process.
9. The method according to claim 1, wherein before determining the corrected gear cutting process, the possibility of changing the tool geometry is enabled or disabled; and/or before determining the corrected gear cutting process, the possibility of changing the process kinematics is enabled or disabled.
10. The method according to claim 1, wherein the determination of the corrected gear cutting process is performed by a nonlinear optimization.
11. The method according to claim 1, wherein the first permissible deviation is assigned first tolerances for one or more of the subsequent toothing deviations: profile deviations, such as the total profile deviation, the profile shape deviation, the profile angle deviation, the pressure angle deviation, and/or the deviations of one or more tooth flank modifications in the profile direction, such as deviations of the vertical crowning, the tip and/or root relief, the profile angle modification, the profile interleaving; flank line deviations, such as the flank line total deviation, the flank line shape deviation, the flank line angle deviation, the spiral angle deviation and/or the deviations of one or more tooth flank modifications in flank direction, such as deviations of width crowning, end reliefs, flank line angle modification, flank line interleaving; pitch deviations, such as the pitch single deviation, the pitch sum deviation, the pitch jump; tooth thickness deviations; concentricity deviations; roundness deviations; runout deviations; Flatness deviations; warping/interleaving; and/or the second permissible deviation is assigned second tolerances for one or more of the subsequent toothing deviations: profile deviations, such as the total profile deviation, the profile shape deviation, the profile angle deviation, the pressure angle deviation, and/or the deviations of one or more tooth flank modifications in the profile direction, such as deviations of the vertical crowning, the tip and/or root relief, the profile angle modification, the profile interleaving; flank line deviations, such as the flank line total deviation, the flank line shape deviation, the flank line angle deviation, the spiral angle deviation and/or the deviations of one or more tooth flank modifications in flank direction, such as deviations of width crowning, end reliefs, flank line angle modification, flank line interleaving; pitch deviations, such as the pitch single deviation, the pitch sum deviation, the pitch jump; tooth thickness deviations; concentricity deviations; roundness deviations; runout deviations; flatness deviations; warping/interleaving; wherein the first tolerances at least partially deviate from or are identical to the second tolerances and/or wherein the toothing deviations associated with the first permissible deviation at least partially deviate from or are identical to the toothing deviations associated with the second permissible deviation.
12. The method according to claim 1, wherein the first permissible deviation of the actual geometry from the nominal geometry for a respective measuring point or a section of the first evaluation area is selected from a range less than or equal to 10 μm, in particular selected from a range less than or equal to 5 μm, and the second permissible deviation of the actual geometry from the nominal geometry for a respective measuring point or a section of the second evaluation area is selected from a range smaller than or equal to 15 μm, in particular selected from a range smaller than or equal to 10 μm.
13. The method according to claim 1, wherein the gear cutting process comprises one or more of the following method steps: machining the workpiece with a tool having a geometrically defined cutting edge, such as gear hobbing, profile milling, gear shaping, hob peeling, bevel gear milling; machining the workpiece with a tool having a geometrically indeterminate cutting edge, such as grinding, lapping, honing; pre-cutting in the soft state of the workpiece; hard machining of the workpiece in the hard state after hardening of the workpiece.
14. The method according to claim 1, wherein workpiece is a gearwheel of a toothed gearing, such as a spur gear, a bevel gear, wherein a plurality of tooth flanks of the gearwheel are machined or produced during machining of the gear by the gear cutting process.
15. A method for machining and measuring workpieces, the method including the following steps: measuring an actual geometry of a tooth flank of a workpiece generated by a gear cutting process, determining a deviation of the actual geometry of the tooth flank from a specified nominal geometry of the tooth flank, and evaluating the deviation, wherein the evaluation of the deviation has the specification that a first permissible deviation of the actual geometry from the nominal geometry is specified for a first evaluation area of the tooth flank, that a second permissible deviation of the actual geometry from the nominal geometry is specified for a second evaluation area of the tooth flank, and that the first permissible deviation is smaller than the second permissible deviation.
16. The method according to claim 15, wherein the first evaluation area is assigned a tooth flank load-bearing area which is at a distance from ends or edges of the tooth flank and/or the second evaluation area is assigned an edge region which has ends or edges of the tooth flank or is adjacent thereto.
17. The method according to claim 15, wherein when the actual geometry of the tooth flank of the workpiece generated by the gear cutting process is measured by the measuring process, a measuring grid with measuring points is detected, when determining the deviation of the actual geometry of the tooth flank from the predetermined nominal geometry of the tooth flank, a deviation of the actual position of the respective measuring point from the nominal position of the respective measuring point is determined for each measuring point of the measuring grid, and a first group of the measuring points is assigned to the first evaluation area and second group of the measuring points is assigned to the second evaluation area.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0091] The disclosure is described in more detail below with reference to drawings illustrating exemplary embodiments. They show schematically in each case:
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DETAILED DESCRIPTION OF THE DRAWINGS
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[0120] First, in method step (A), a workpiece 2 is machined by means of a gear cutting process, wherein tooth flanks 4 of the workpiece 2 are produced. For this purpose, the workpiece 2 is first provided as an untoothed blank 2, as shown in
[0121] The blank 2 is machined by hobbing in the soft state, so that the blank 2 has not been hardened before hobbing. The gear cutting process therefore features the “gear hobbing” machining step, as shown schematically in
[0122] Subsequently, in a method step (B), an actual geometry of the tooth flanks 4 of the workpiece 2 generated by means of hobbing is measured by means of a measuring method.
[0123] For this purpose, a measuring grid 8 is defined, as shown in
[0124] The measuring procedure is carried out by means of a coordinate measuring machine 100, wherein a measuring probe 12 scans the measuring grid 8 for one or more tooth flanks 4 or for each of the tooth flanks 4 in order to determine the actual position of the measuring points 10 of the measuring grid 8 for the measured tooth flanks 4 (
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[0126] Then, in a method step (C), a deviation of the actual geometry of the measured tooth flanks 4 from a predetermined nominal geometry of the tooth flanks 4 is determined on the basis of the measuring points 10. The determination of the deviation can be computer-aided by means of a measuring computer 14 of the coordinate measuring machine or by means of an external computer 16 which is not part of the coordinate measuring machine.
[0127] In a method step (D), a corrected gear cutting process is determined for at least partial reduction of the deviation, with the determination of the corrected gear cutting process for at least partial reduction of the deviation having the specifications that a first permissible deviation of the actual geometry from the nominal geometry is specified for a first evaluation area AB1 of the tooth flank 4, that a second permissible deviation of the actual geometry from the nominal geometry is specified for a second evaluation area AB2 of the tooth flank 4, and that the first permissible deviation is smaller than the second permissible deviation. A first correction step or a first correction loop is therefore performed for the “gear hobbing” machining step of the gear cutting process.
[0128] The first evaluation area AB1 has a section TB1 of the tooth flank 4. The first evaluation area AB1 therefore corresponds to the first section TB1 (
[0129] The second evaluation area AB2 has two sections of the tooth flank, namely a section TB2 and a section TB3. The second evaluation area therefore corresponds to the sections TB2 and TB3. The sections TB2 and TB3 are arranged at a distance from each other (
[0130] All those measuring points 10 which are arranged within the first evaluation area AB1 form a first group G1 of measuring points 10 (
[0131] When determining the corrected gear cutting process by the first correction step for the “gear hobbing” machining step, narrower tolerances or smaller permissible deviations are therefore taken into account for the measuring points 10 of the first group G1 than for the second group G2 of measuring points 10. Furthermore, for a mathematical optimization for at least partial reduction of the deviation, a first weighting W1 is specified for a deviation of the first evaluation area AB1 of the tooth flank 4 and a second weighting W2 is specified for a deviation of the second evaluation area AB2 of the tooth flank 4, with the first weighting W1 being greater than the second weighting W2. In this case, the sum S of the weighted deviations is minimized during the optimization, with e.g. S=(W1*deviation AB1)+(W2*deviation AB2). It is understood that such a sum to be minimized can also be formed from weighted deviations of the individual measuring points of the evaluation areas or from weighted parameters or quality characteristics of the toothing, which have been calculated from the deviations of the individual measuring values or measuring points.
[0132] With the corrected gear hobbing process, deviations of the evaluation area AB1 are therefore corrected in a prioritized manner in order to produce the smallest possible deviations in the evaluation area AB1, while the deviations in the evaluation area AB2 are allowed to be larger compared to the evaluation area AB1.
[0133] The first permissible deviation may be associated with first tolerances for one or more of the subsequent toothing deviations and/or toothing modifications: Profile deviations, such as the profile total deviation, the profile shape deviation, the profile angle deviation, the meshing angle deviation or the like, and/or the deviations of one or more tooth flank modifications in the profile direction, such as deviations of the vertical crowning, the tip and/or root relief, the profile angle modification, the profile interleaving or the like; flank line deviations, such as the flank line total deviation, the flank line shape deviation, the flank line angle deviation, the spiral angle deviation or the like and/or the deviations of one or more tooth flank modifications in flank direction, such as deviations of the width crowning, the end relief, the flank line angle modification, the flank line interleaving or the like; pitch deviations, such as the pitch single deviation, the pitch sum deviation, the pitch jump or the like; tooth thickness deviations; concentricity deviations.
[0134] The second permissible deviation can be assigned second tolerances for one or more of the following toothing deviations and/or toothing modifications: Profile deviations, such as the profile total deviation, the profile shape deviation, the profile angle deviation, the meshing angle deviation or the like, and/or the deviations of one or more tooth flank modifications in the profile direction, such as deviations of the vertical crowning, the tip and/or root relief, the profile angle modification, the profile interleaving or the like; flank line deviations, such as the flank line total deviation, the flank line shape deviation, the flank line angle deviation, the spiral angle deviation or the like and/or the deviations of one or more tooth flank modifications in flank direction, such as deviations of width crowning, end relief, flank line angle modification, flank line interleaving or the like; pitch deviations, such as the pitch single deviation, the pitch sum deviation, the pitch jump or the like; tooth thickness deviations; concentricity deviations.
[0135] For example, it can be provided that a smaller tolerance for the flank line angle deviation can be specified for the first evaluation area AB1 than for the second evaluation area AB2. Further it can be provided, for example, that for the first evaluation area AB1 a smaller tolerance for the vertical crowning is preset than for the second evaluation area AB2. The first permissible deviation and the second permissible deviation therefore each have, in particular, several permissible tolerances for two or more parameters or quality characteristics of the toothing 2.
[0136] In machining step (E), another workpiece 2 is machined using the corrected gear cutting process, wherein the corrected gear cutting process has modified process kinematics for the “gear hobbing” machining step compared to the gear cutting process. Since the hobbing is a machining of the workpiece 2 with a non-dressable tool with a geometrically determined cutting edge, namely the hob 6, the possibility of changing the tool geometry is blocked and the possibility of changing the process kinematics is enabled before determining the corrected gear cutting process for the “gear hobbing” machining step.
[0137] After the further workpiece 2 has been manufactured with the corrected gear cutting process in the “gear hobbing” machining step, the workpiece geometry or the tooth flanks 4 can be checked again to determine any further need for correction or to check the effectiveness of the correction.
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[0139] The section TB4 corresponds to a load-bearing area of the tooth flank 4 that is at a distance from the tip edge K1, the tooth root Z1 and the ends E1, E2 of the tooth flank 4. In the present case, the section TB4 also corresponds to a section of the tooth flank 4 for which a predefined load threshold or a predefined load criterion is exceeded during operation.
[0140] In the present case, the section TB5 corresponds to an area of the tooth flank 4 that is adjacent to the tip edge K1, the tooth root Z1 and the ends E1, E2 of the tooth flank 4. In the present case, the section TB5 also corresponds to a section of the tooth flank 4 for which the load falls below a specified load threshold or a specified load criterion during operation.
[0141] For the first evaluation area AB1 of the tooth flank 4 according to
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[0143] For the first evaluation area AB1 of the tooth flank 4 according to
[0144] Therefore, the result of the first correction step is a corrected hobbing, which is a machining step of the corrected gear cutting process, and which allows maintaining different tolerances in prioritized areas of the tooth flanks 4.
[0145] In addition to the hobbing process described above, the gear cutting process can have one or more further machining steps which can be corrected by means of an associated correction step.
[0146] For example, it may be provided that the workpiece 2 is hardened after hobbing and then ground.
[0147] It can therefore be provided that the gear cutting process comprises the machining step “generating grinding”, so that in method step (A) a machining of previously hobbed tooth flanks 4 of the workpiece 2 is performed by means of a grinding tool 18 (
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[0150] The first evaluation area and the second evaluation area as well as the permissible deviations correspond to those evaluation areas and deviations which have already been described for the first aspect of the disclosure. All variants and embodiments of the evaluation areas and the permissible deviations that have been described for the first aspect of the disclosure therefore also apply to the second aspect of the disclosure and can be transferred in an identical manner to the second aspect of the disclosure.
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[0152] The bevel gear 20 can be machined and measured analogously to the spur gear described above or the example described below. A measuring grid 24 is shown for a tooth 22 of the bevel gear, to which evaluation areas and sections of a tooth flank 26 with a corresponding permissible deviation and weightings can be assigned analogously to
[0153] It can be provided that during machining of the workpiece 20 by means of the gear cutting process all tooth flanks 26 of the workpiece 20 are machined, wherein during measuring of the actual geometry generated by means of the gear cutting process two or more tooth flanks 26 of the workpiece 20 are measured by means of the measuring method; wherein, when determining deviations of the actual geometry of the respectively measured tooth flanks 26 from the predetermined nominal geometry, a mean deviation is determined from the deviations of the respectively measured tooth flanks 26; and wherein, when determining the corrected gear cutting process for at least partial reduction of the deviations, the mean deviation is used and applies to all tooth flanks 26.
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[0155] None of the measuring points 10 assigned to the first evaluation area AB1 (
[0156] The contact path 30 has been scanned with a higher resolution than the grid lines i, j of the measuring grid 32.