METHOD FOR THE GEAR MANUFACTURING MACHINING OF A WORKPIECE
20180297135 ยท 2018-10-18
Inventors
Cpc classification
B23F5/163
PERFORMING OPERATIONS; TRANSPORTING
B23F21/005
PERFORMING OPERATIONS; TRANSPORTING
B23Q15/013
PERFORMING OPERATIONS; TRANSPORTING
B23F17/006
PERFORMING OPERATIONS; TRANSPORTING
B23F13/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23F19/10
PERFORMING OPERATIONS; TRANSPORTING
B23F5/16
PERFORMING OPERATIONS; TRANSPORTING
B23Q15/013
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present disclosure relates to a method for the gear manufacturing machining of a workpiece in which a hobbing machining of the workpiece takes place to generate a gearing geometry of the workpiece, wherein the workpiece is gear manufacturing machined by gear skiving in addition to the hobbing machining.
Claims
1. A method for the gear manufacturing machining of a workpiece, comprising the steps: hobbing machining of the workpiece to generate a gearing geometry of the workpiece, and gear manufacturing machining of the workpiece by gear skiving.
2. The method in accordance with claim 1, wherein the hobbing machining and the gear skiving take place with the same gear cutting machine, wherein the hobbing machining and the gear skiving take place using the same fixture of the workpiece in a workpiece holder of the gear cutting machine and/or with a hobbing tool used for hobbing machining and a gear skiving tool used for gear skiving held in the same tool holder of the gear cutting machine and/or traveled by the axes of the same machining head of the gear cutting machine at least on the carrying out of the respective machining step.
3. The method in accordance with claim 2, wherein the hobbing tool and the gear skiving tool are fixed on the same tool arbor and/or wherein the gear cutting machine has two tool holders arranged at a machining head and/or an automatic tool changer for changing between the hobbing tool and the gear skiving tool.
4. The method in accordance with claim 1, wherein a feed movement of the hobbing tool and the gear skiving tool respectively takes place in parallel with an axis of the workpiece holder in at least one of the hobbing machining or in the gear skiving, wherein a rotational movement of the workpiece holder is coupled to the feed movement and/or to a rotational movement of the tool holder.
5. The method in accordance with claim 1, wherein the machining head of the gear cutting machine is pivoted relative to the axis of the workpiece holder between the two machining steps about a pivot axis of the machining head extending perpendicular to the axis of the workpiece holder and/or of the tool holder, and wherein the tool holder in which the tool for the hobbing machining and the tool for the gear skiving are held is shifted between the two machining steps relative to the workpiece via a slide of a machining head supporting the workpiece holder travelable in parallel with the axis of rotation of the tool holder and/or via two axes of movement of a machining head supporting the workpiece holder fixing a plane perpendicular to the pivot axis.
6. The method in accordance with claim 1, wherein the hobbing machining takes place at the non-hardened workpiece and/or is at least used for the roughing machining of a gearing from a blank of the workpiece and/or wherein the gear skiving machining takes place at the non-hardened workpiece and/or is at least used for the finishing of a gearing.
7. The method in accordance with claim 1, wherein the hobbing machining and the gear skiving machining are used for manufacturing the same gearing, with a roughing machining for manufacturing a gearing first carried out and following on from this a gear skiving machining for finishing a gearing is carried out at the toothed workpiece.
8. The method in accordance with claim 7, wherein the gearing is a worm gearing for manufacturing a drive element having a worm gearing of a steering drive of a vehicle.
9. The method in accordance with claim 8, wherein the hobbing machining takes place using a disc-shaped profile cutter that rotates independently of the rotational movement of the workpiece holder, with the profile cutter traveled in parallel with the axis of the workpiece holder during the hobbing machining while the workpiece is rotated about its axis such that the profile cutter generates a worm thread and/or wherein the hobbing machining takes place at an axial cross angle dependent on the lead angle of the worm gearing, with the axial cross angle approximately corresponding to the lead angle.
10. The method in accordance with claim 1, wherein the hobbing machining and the gear skiving machining are used for manufacturing two different gearing arrangements of the workpiece, with a hobbing machining carried out for manufacturing a first gearing and with a gear skiving machining carried out for manufacturing a second gearing, with the first gearing having a larger diameter than the second gearing and/or with an interference contour for the second gearing.
11. The method in accordance with claim 10, wherein the gearing or the gearing arrangements is a spur gearing, in particular for manufacturing a workpiece having multiple gearing, in particular a shaft having at least two spur gearing arrangements arranged next to one another, in particular having different diameters and/or having an interference contour close to an end side of one of the gearing arrangements.
12. The method in accordance with claim 11, wherein the hobbing machining takes place by a hob whose rotational movement is coupled to the rotational movement of the workpiece holder, with the hob traveled in parallel with the axis of the workpiece holder during the hobbing machining; and/or wherein the gear skiving takes place by a generating coupling between the gear skiving tool and the workpiece and the gear skiving tool traveled in parallel with the axis of the workpiece holder during the gear skiving; and/or wherein the hobbing machining is carried out at an axial cross angle between the hobbing tool and the workpiece in the range of 90 +/45 and the gear skiving machining is carried out at an axial cross angle between the hobbing tool and the workpiece in the range of +/45.
13. A gear cutting machine comprising a workpiece holder and a tool holder that is travelable via movement axes of the gear cutting machine with respect to the workpiece holder, with the tool holder arranged at a machining head that is travelable over movement axes of the gear cutting machine, with the gear cutting machine having a control for controlling the movement axes of the gear cutting machine that has a function for carrying out a method in accordance with one of the previous claims, in particular a function for an automated carrying out of a method in accordance with one of the preceding claims for manufacturing a plurality of toothed workpieces.
14. The gear cutting machine of claim 13, wherein the machining head of the gear cutting machine having the tool holder has a pivot axis that stands perpendicular on the axis of the workpiece holder, with the pivot axis having a pivot angle of more than 90, or wherein the axis of the tool holder is pivotable by the pivot axis of the machining head in a range from 20 to +90 relative to the axis of the workpiece holder.
15. Software for controlling a gear cutting machine, in particular for controlling a gear cutting machine in accordance with one of the claims 13, having a function for carrying out a method in accordance with one of the preceding claims, the software comprising code for controlling the gear cutting machine to perform a hobbing machining of the workpiece to generate a gearing geometry of the workpiece, and code for controlling the gear cutting machine to further perform a gear skiving of the gearing geometry of the workpiece.
16. The method in accordance with claim 1, wherein the hobbing machining takes place at a first axial cross angle between the tool and the workpiece and the gear skiving machining takes place at a second axial cross angle between the tool and the workpiece, with the difference between the first and second axial cross angles amounting to at least one of more than 45 or less than 135; and wherein the tool holder in which the tool for the hobbing machining and the tool for the gear skiving are held is shifted between the two machining steps relative to the workpiece, via a slide of a machining head supporting the workpiece holder travelable in parallel with the axis of rotation of the tool holder and/or via two axes of movement of a machining head supporting the workpiece holder fixing a plane perpendicular to the pivot axis.
17. The method in accordance with claim 8, wherein the gear skiving takes place by a generating coupling between the gear skiving tool and the workpiece and the gear skiving tool is traveled in parallel with the axis of the workpiece holder during gear skiving, with the gear skiving tool having a step cut and/or wherein the gear skiving takes place at an axial cross angle differing from 90, with the angle of the step cut and/or the difference of the axial cross angle from 90 approximately corresponding to the lead angle.
18. The method in accordance with claim 17, wherein the gear skiving machining is carried out at an axial cross angle between the hobbing tool and the workpiece in the range of 90 +/40.
19. The method in accordance with claim 9, wherein the hobbing machining is carried out at an axial cross angle between the hobbing tool and the workpiece in the range from +/5 and +/40.
Description
BRIEF DESCRIPTION OF THE FIGURES
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DETAILED DESCRIPTION
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[0085] The tool holder 2 has a tool spindle in which one or more tools arranged at a tool arbor can be fixed. The tool holder 2 has an axis of rotation B1 that can be set into rotation by a corresponding drive of the gear cutting machine. The tools can be unilaterally supported in the tool holder in a first embodiment. The tool holder 2, however, has a counter-bearing so that the tool arbor supporting the tools is arranged in the tool holder 2 supported at two sides.
[0086] The workpiece holder 3 allows the holding of workpieces to machine them by tools held in the tool holder 2. The workpiece holder 3 has an axis of rotation B2 by which the workpiece holder 3 can be set into rotation via a drive of the gear cutting machine. The workpiece holder 3 is arranged at a machine table 9 above the axis of rotation B2. The workpiece holder 3 permits a unilateral support of the workpieces in a first embodiment. The workpiece holder 3, however, also has a counter-bearing so that the workpieces are supported at two sides in the workpiece holder 3.
[0087] In
[0088] A machine column 7 having the machining head 4 is provided on the machine bed 20. The machine column 7 is travelable via a linear axis X1 by which the axial spacing between the axis of rotation B1 of the tool holder and the axis of rotation B2 of the workpiece holder 3 is variable. The linear axis X1 for this purpose runs perpendicular to a plane defined by the direction of the axes of rotation B1 and B2.
[0089] A guide 8 is provided at the machine column 7 and a slide 6 of the machining head 4 is travelable along it. The machining head can hereby be traveled along a linear axis Z1 that extends in parallel with the axis of rotation B2 of the workpiece holder 3.
[0090] The machining head 4 with the tool holder 2 is arranged at the slide 6 via a pivot axis A1. The pivot axis A1 extends in parallel with the linear axis X1 and/or stands perpendicular on a plane spanned by the directions of the axes of rotation B1 and B2. The pivot axis A1 particularly intersects the axes of rotation B1 and B2 of the tool holder 2 or workpiece holder 3.
[0091] The machining head 4 in accordance with the embodiment furthermore has a slide 5 that provides a linear axis V1 via which the tool holder 2 can be shifted in the direction of its axis of rotation B1. In the embodiment, the pivot axis A1 is arranged between the two linear axes Z1 and V1.
[0092] Alternatively to the embodiment shown having a shift axis V1, it would be conceivable to provide an axis Y1 via which the machine column 7 and/or the slide 6 would be travelable in a direction perpendicular to the linear axes X1 and Z1. A travel movement in the direction of the axis of rotation B1 of the tool holder 2 could then be generated by a superposition of linear movements of the axes Z1 and Y1.
[0093] A counter-column for holding the tailstock can, for example, be installed on the table frame 10, but also other automation devices for changing the workpieces or another link to an automation system can be arranged.
[0094] Other mechanical embodiments of the gear cutting machine are likewise conceivable for providing the above-describes axes of rotation, linear axes and pivot axes.
[0095] In typically hobbing processes, an axial cross angle required for the manufacture of helical gearing arrangements is provided between the axes of rotation B1 and B2 by the pivoting about the pivot axis A1. In hobbing machines known from the prior art, the pivot axis A1 therefore typically has a pivot angle range of +/45 about a pivot position in which the axis of rotation B1 of the tool holder 2 stands perpendicular on the axis of rotation B2 of the workpiece holder 3.
[0096] In accordance with a first aspect of disclosed herein, the pivot axis A1 of the gear cutting machine in contrast has a pivot angle range that permits a pivoting of the axis of rotation B1 of the tool holder 2 from a position perpendicular to the axis of rotation B2 of the workpiece holder 3 into a position in parallel with the axis of rotation B2 of the workpiece holder 3. Alternatively or additionally, the pivot angle range is greater than 90. For example, the pivot angle range can comprise a range from 20 to +100 with respect to a position of the axis of rotation B1 that stands perpendicular on the axis of rotation B2. In the embodiment, the pivot angle range amounts, for example to 45 to +110 with respect to the position of the axis of rotation B1 that stands perpendicular on the axis of rotation B2.
[0097] The larger pivot angle range of the A1 axis can be used to carry out both a hobbing method and a gear skiving method by means of the same machining head at a workpiece held in the workpiece holder 3. The hobbing tool or gear skiving tool used for this purpose can be held in the tool holder 2 for this purpose. The hobbing tool and the gear skiving tool are fixed on an arbor and are held together in the tool holder 2. The very different axial cross angles required for both the hobbing machining and for the gear skiving machining can be provided by the large pivot angle range of the pivot axis A1.
[0098] In accordance with a second aspect, the control of the gear cutting machine is designed such that one of the gear cutting methods described in the following can be carried out on the machine. The control has a function for the automatic carrying out of one of the gear cutting methods described in the following for this purpose. A plurality of identical workpieces can be manufactured in an automated manner on the gear cutting machine by this function.
[0099] A gear cutting machine in accordance with the second aspect has the pivot angle range in accordance with the first aspect. Alternative construction designs of the gear cutting machine in accordance with the second aspect are likewise conceivable, however.
[0100] In the following, a first embodiment and a second embodiment will be described in more detail. Both embodiments of the methods will be described with reference to the embodiment of a gear cutting machine shown in
[0101] It is common to both embodiments of the method described herein that both a hobbing machining and a gear skiving machining of the workpiece takes place on the gear cutting machine. In the embodiment, both the hobbing machining and the gear skiving take place using the same fixing of the workpiece in the workpiece holder 3. Furthermore, in the embodiment, a hobbing tool and a gear skiving tool are used that are held in the tool holder 2 of the gear cutting machine and that are traveled via the axes of movement of the machining head 4. In accordance with the preferred embodiment shown in the following, the hobbing tool and the gear skiving tool are fixed on the same tool arbor and are therefore held together in the tool holder 2. Alternatively, the use of an automatic tool changer for changing the tools between the two machining steps or the use of two tool holders at the machining head 4 would be conceivable.
[0102] In the first embodiment of the method shown with reference to
[0103] The first embodiment therefore combines the strengths of hobbing machining and of gear skiving and balances the respective weaknesses of these methods. The hobbing machining permits high cutting performances with relatively low tool wear, but has the disadvantage with large tool feeds of the low quality of the surface geometry. A high quality of the surface geometry can be achieved by the gear skiving. The high wear of the tool during gear skiving is compensated by the fact that only the stock still left as part of the hobbing machining or rough machining has to be removed by the gear skiving, such that the required cutting performance and thus also the wear of the gear skiving tool is correspondingly reduced.
[0104] In accordance with the first embodiment, the hobbing tool is used to generate a gearing in a first machining step. This gearing can be generated from the non-hardened workpiece blank by the hobbing machining. In a second step, this gearing is then further machined by the gear skiving and a high quality of the surface geometry is hereby achieved. The gear skiving also takes place at the non-hardened workpiece.
[0105] The machining head 4 is pivoted with the tool holder 2 about the A1 axis between the hobbing machining step and the gear skiving step to provide the axial cross angles, that are required for the hobbing machining and the gear skiving machining, between the axis of rotation B1 of the tool holder 2 and the axis of rotation B2 of the workpiece holder 3.
[0106] In the first embodiment of the method as shown with reference to
[0107] The hobbing machining step in the first embodiment is shown in
[0108] The tool holder 2 in which the hobbing tool 13 is clamped is pivoted via the A1 axis in dependence on the desired lead angle of the worm geometry of the workpiece 15 with respect to the axis of rotation B2 of the workpiece holder 3. The axial cross angle between the axes of rotation B1 and B2 for this purpose in particular approximately corresponds to the desired lead angle so that the plane defined by the profile cutter approximately corresponds to the pitch of the thread of the worm geometry generated by the hobbing tool 13.
[0109] The hobbing tool 13 rotates about the axis B1 to generate the worm geometry. The rotational movement of the tool 13 about the axis of rotation B1 here only serves the material removal and does not therefore have to be coupled with the rotational movement of the workpiece 15 about the axis B2.
[0110] After the corresponding delivery of the hobbing tool 13 to the workpiece 15 via the X1 axis, a travel movement of the machining head takes place in parallel with the axis of rotation B2 of the workpiece holder 3, in particular via the Z1 axis. A rotational movement of the workpiece 15 about the B2 axis of the tool holder 3 is coupled hereto so that a worm thread is generated by the superposition of the movement in parallel with the B2 axis and the rotational movement about the B2 axis. The length of the travel movement in parallel with the axis of rotation B2 therefore corresponds to the width of the worm geometry to be generated. If the worm geometry has a plurality of threads, a plurality of machining steps having a starting point displaced in the Z1 direction or in the direction of rotation are necessary.
[0111] The manufacture of a thread of the worm geometry by the hobbing machining can take place in one or more work strokes. If a plurality of work strokes are used, the axial spacing can be reduced between the individual work strokes, in particular by a further delivery of the tool via the X1 axis in order thus to distribute the total required material removal over a plurality of work strokes.
[0112] In one aspect, the worm geometry of the workpiece is manufactured by the hobbing machining. In this case, the pivot angle range of the A1 axis only has to be able to provide the large axial cross angles required for the hobbing machining, for example by a pivot angle range of the A1 axis that at least comprises a range of +/15 about an axial cross angle of 90.
[0113] In accordance with the first embodiment, however, the gearing generated by the hobbing tool, in particular the worm geometry, is reworked by means of the gear skiving tool 14 in a second machining step. This second machining step is shown in
[0114] To carry out the gear skiving, a pivoting of the machining head takes place about the A1 axis to provide the axial cross angle that is required for the gear skiving, between the rotational axes B1 and B2. In addition, a shift movement of the tool holder 2 takes place, in particular via the V1 axis, in order now to bring the gear skiving tool 14 held in the tool holder 2 axially offset from the hobbing tool 13 into engagement with the worm geometry.
[0115] The gear skiving machining takes place by a rotation of the gear skiving tool about the axis of rotation B1 coupled with the rotation of the workpiece 15 about the axis of rotation B2. The machining head is furthermore traveled along the width of the worm geometry via the Z1 axis in parallel with the B2 axis of the workpiece holder 3.
[0116] The lead angle of the worm geometry amounts to between 5 and 40, further between 10 and 20. The change of the axial cross angle between the axes B1 and B2 and thus the pivot movement of the pivot axis A1 between the hobbing machining step and the gear skiving step amounts to more than 50 and can, for example, be in the range between 50 and 130, in particular in the range between 60 and 120.
[0117] Since a worm geometry is generated, the axial cross angle in gear skiving approximately corresponds to that axial cross angle that is otherwise required for hobbing spur gearing arrangements. A gear cutting machine adapted for hobbing machining can therefore be used for gear skiving of a worm geometry. The gear cutting machine can, as described above, also be used to hob the worm gearing due to the larger pivot angle that is available.
[0118] In the first embodiment, in which the hobbing machining is used for generating a gearing that is then finished via the gear skiving can, however, also be used for generating spur gearing arrangements. The method steps are the same that were shown with respect to the already described embodiment. Only the axial cross angles differ from the described embodiment and are displaced by approximately 90 with respect to the described embodiment.
[0119] Instead of a profile cutter, in a possible alternative embodiment, the first embodiment is carried out using a hob. In this case, the method only differs from the method shown to the extent that the rotational movement of the tool axis B1 is also coupled with the rotational movement of the workpiece B2 in this hob. The use of a hob is in particular recommended in the manufacture of spur gear arrangements.
[0120] A second embodiment will now be described in more detail with reference to
[0121] The hobbing machining and the gear skiving machining are used in this embodiment in accordance with a first aspect for manufacturing different gearing arrangements 17 and 18 of the same workpiece 16. This aspect of the second embodiment makes use of the fact that gear arrangements can also be generated by the gear skiving that would not be able to be manufactured within the framework of hobbing due to interference contours.
[0122] The second embodiment can in particular be used to manufacture a first gearing 17 with a larger diameter by a hobbing machining and a second gearing 18 with a smaller diameter or with an interference contour relevant to the gearing machining by a gear skiving machining. In this case, the higher wear of the gear skiving tool is accepted in order to achieve a manufacturing capability of the workpiece at all on only one machine. In accordance with the prior art, in contrast, if the larger gearing 17 is to be manufactured by a gearing hobbing, the workpiece would have to be changed to a different machine to manufacture the smaller gearing 18 by a shaping process. In contrast, the methods described herein allow the manufacture of such a workpiece in one machine and in one fixture by the combination of a hobbing machining and a gear skiving machining.
[0123] The two gearing arrangements 17 and 18 on the workpiece 16 are arranged axially offset at the workpiece 16 in the embodiment. They can be positioned so closely next to one another that the manufacture of the gearing 18 with a smaller diameter is no longer possible by means of hobbing machining since a hob used for manufacturing the gearing 18 would damage the gearing 17 having a larger diameter.
[0124] A one-sided or two-sided axial interference contour can in contrast be arranged considerably closer to the gearing for the gear skiving, as with a hobbed gearing, since the gear skiving method requires a considerably smaller overrun to manufacture the gearing so that it can be used for manufacturing the gearing 18.
[0125] In a second aspect, the second embodiment is used for the manufacture of spur gearing arrangements 17 and 18. The spur gearing arrangements can be straight gearing arrangements or helical gearing arrangements.
[0126] The hobbing machining step of the second embodiment of the method is shown in
[0127] A hob 13 is used for the hobbing machining in the embodiment to manufacture the first gearing 17 having the larger diameter. The hob 13 rotates about the axis of rotation B1 of the tool holder 2 in generating coupling with the rotation of the workpiece 16 about the axis of rotation B2 of the workpiece holder 3. The machining head 4 is furthermore in particular guided with the hob 13 along the workpiece 16 via the linear axis Z1 in parallel with the axis of rotation B2 of the workpiece in the width direction.
[0128] The hobbing machining can, as described in the first embodiment, take place in one or more work strokes. The machining takes place in a plurality of work strokes, in particular by a rough machining and a finishing.
[0129] Alternatively to the use of a hob, a profile cutter can also be used. In this case, however, every tooth space has to be manufactured by at least one work stroke.
[0130] The axial cross angle between the axis of rotation B1 and the axis of rotation B2 substantially corresponds in the gear hobbing machining to the lead angle of the first gearing 17 or to 90 minus the helix angle of the first gearing 17, with the lead angle of the tool additionally having to be taken into account.
[0131] The gear skiving machining in accordance with the second embodiment is shown in
[0132] Although the second gearing 18 in the embodiment is a straight gearing, the hobbing tool 14 is used with an axial cross angle differing from a parallel alignment between the axes B1 and B2 and has a helical gearing in this embodiment. The movement required for the gear skiving is hereby generated. The axial cross angle also does not correspond to the helix angle of the gearing and/or the gear skiving tool 14 has a different helix angle than the gearing to be manufactured to generate and/or to increase the corresponding relative movement for the gear skiving in the manufacture of helical gearing arrangements.
[0133] In the second embodiment of, there is no preferred order of the two machining steps, i.e. of the hobbing machining and of the gear skiving machining since they are used for machining different gearing arrangements.
[0134] To be able to change from the one machining step to the other, however, the machining head also has to be pivoted about the pivot axis A1 here. The exact magnitude of the required pivot movement inter alia depends on the respective helical angles of the gearing arrangements 17 and 18 and on the tool configuration.
[0135] The required pivot angle range is typically greater than 50 and can, for example, be in a range from 50 to 130, in the range from 60 to 120.
[0136] A shift movement is also carried out in addition to the pivot movement about the A1 axis in the second embodiment on a change between the two machining steps to bring the respective other tool into engagement with the respective gearing to be machined.
[0137] As shown in the Figures with respect to the respective methods, the workpiece holders and the tool holder each have counter-bearings so that the workpiece and the tool are clamped at two sides. This is significant with the high cutting forces occurring within the framework of the hobbing.
[0138] The counter-bearings are designed in as narrow a manner as possible to provide a corresponding freedom of movement in an axial direction for the gear skiving process.