Method for grinding machining of bevel gears in the single-indexing method

Abstract

A method for grinding bevel gears (1), wherein a first grinding tool (2) is used during a first method section and a second grinding tool is used during a second method section. A measurement system (30) is used to carry out a measuring procedure, in which sampling values can be ascertained for at least a part of first flanks of the bevel gear workpiece (1), which enable a statement about the concentricity error of this bevel gear workpiece (1) in the present chucking. Concentricity correction dimensions are ascertained by computer on the basis of the sampling values, and an adaptation of machining movements of the second method section is performed on the basis of the concentricity correction dimensions.

Claims

1. A method for grinding bevel gears comprising: a) fastening a first grinding tool on a tool spindle of a grinding machine, b) fastening a first workpiece on a workpiece spindle of the grinding machine, c) performing a CNC-controlled first single-indexing grinding procedure using the first grinding tool, wherein all first tooth flanks of the first workpiece are machined by grinding step-by-step during said first single-indexing grinding procedure, d) separating the first workpiece from the workpiece spindle, e) at a later point in time, re-chucking the first workpiece on the workpiece spindle of the grinding machine, which carries a second grinding tool on the tool spindle, f) performing a measurement procedure using a sensor of the grinding machine to obtain sampling values at least for a part of the first tooth flanks, and determining a concentricity error of the first workpiece After said re-chucking, g) determining concentricity correction dimensions using a computer, and h) performing a CNC-controlled second single-indexing grinding procedure using the second grinding tool, wherein all second tooth flanks of the first workpiece are machined by grinding step-by-step during said second single-indexing grinding procedure, and executing machining movements during the second single-indexing grinding procedure based on said concentricity correction dimensions.

2. The method according to claim 1, including applying the concentricity correction dimensions to reduce or prevent workpiece teeth thickness errors.

3. The method according to claim 1, including applying different machine settings during the first single-indexing grinding procedure than during the second single-indexing grinding procedure, wherein machine settings of the second single-indexing grinding procedure are modified by applying the concentricity correction dimensions.

4. The method according to claim 2, including applying different machine settings during the first single-indexing grinding procedure than during the second single-indexing grinding procedure, wherein machine settings of the second single-indexing grinding procedure are modified by applying the concentricity correction dimensions.

5. The method according to claim 1, wherein the first tooth flanks have a different radius of curvature than the second tooth flanks.

6. The method according to claim 2, wherein the first tooth flanks have a different radius of curvature than the second tooth flanks.

7. The method according to claim 1, wherein the bevel gears are spiral-toothed bevel gears.

8. The method according to claim 2, wherein the bevel gears are spiral-toothed bevel gears.

9. The method according to claim 1, wherein the first grinding tool and the second grinding tool are cup grinders or conical grinding tools.

10. The method according to claim 2, wherein the first grinding tool and the second grinding tool are cup grinders or conical grinding tools.

11. The method according to claim 1, wherein a first batch comprising multiple workpieces are first successively machined using said first single-indexing grinding procedure using the first grinding tool, then re-chucked successively, workpiece by workpiece, and machined using the second single-indexing grinding procedure using the second grinding tool after determining concentricity correction dimensions individually for each workpiece of the first batch.

12. The method according to claim 1, wherein a first batch comprising multiple workpieces are first successively machined using said first single-indexing grinding procedure using the first grinding tool, then re-chucked successively, workpiece by workpiece, and machined using the second single-indexing grinding procedure using the second grinding tool after determining concentricity correction dimensions individually for each workpiece of the first batch.

13. The method according to claim 1, wherein the grinding machine is a single-spindle bevel gear grinding machine.

14. The method according to claim 2, wherein the grinding machine is a single-spindle bevel gear grinding machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A shows a very schematic view of a cup grinding wheel, which is mounted in a known way and which machines a concave flank of a tooth gap of a crown gear workpiece;

(2) FIG. 1B shows a very schematic sectional view of the cup grinding wheel according to FIG. 1A along section line X1-X1;

(3) FIG. 2 shows a schematic view of a part of a first grinding machine, having a cup grinding wheel which is mounted so it is rotatable on a tool spindle, and having a bevel gear workpiece to be machined, which is mounted so it is rotatable on a workpiece spindle, wherein the cup grinding wheel and the bevel gear workpiece are not engaged at the moment shown;

(4) FIG. 3 shows a simplified perspective view of a second grinding machine having a cup grinding wheel which is arranged suspended, and which is mounted so it is rotatable on a tool spindle, and having a bevel gear workpiece to be machined, which is mounted so it is rotatable on a workpiece spindle, wherein the cup grinding wheel and the bevel gear workpiece are not engaged at the moment shown;

(5) FIG. 4A shows a graphic illustration of the total deviation of the tooth gaps of a bevel gear, wherein the deviation of the convex flanks are shown on top and the deviation of the concave flanks are shown on the bottom in the illustration;

(6) FIG. 4B shows a graphic illustration of two curve sequences, wherein the curve sequence of the convex flanks is shown on top and the curve sequence of the concave flanks is shown on the bottom in the illustration;

(7) FIG. 5A shows a graphic illustration of the total deviation of the tooth gaps of a bevel gear which was machined according to an embodiment of the invention, wherein the deviations of the convex flanks are shown on top and the deviations of the concave flanks are shown on the bottom in the illustration;

(8) FIG. 5B shows a graphic illustration of two curve sequences, wherein the curve sequence of the convex flanks is shown on top and the curve sequence of the concave flanks is shown on the bottom in the illustration.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(9) Terms are used in conjunction with the present description are also used in relevant publications and patents. However, it is to be noted that the use of these terms is only to serve for better understanding. The inventive ideas and the scope of protection of the claims for protection are not to be restricted in the interpretation by the specific selection of the terms. The invention may readily be transferred to other term systems and/or technical fields. The terms are to be applied accordingly in other technical fields.

(10) A device 20, comprises, as schematically shown in FIG. 2, a workpiece spindle 22, which is designed to accommodate a bevel gear workpiece 1 (in the form of a stylized crown wheel here). In addition, it comprises a tool spindle 21 for accommodating a grinding tool 2 (in the form of a cup grinding wheel here) and multiple drives (for example, B1, B2, and further drives, which are not shown in the figures) for machining the bevel gear workpiece 1. The grinding tool 2 executes a rotation 1 about the axis of rotation R1 of the tool spindle 21 during the machining of the bevel gear workpiece 1. The grinding tool 2 engages in the bevel gear workpiece 1, as shown in FIG. 1A on the basis of a spiral-toothed crown gear, for example, to remove material. Since it is a so-called single-indexing grinding method, the bevel gear workpiece 1 executes an indexing rotation B about the axis of rotation R2 after each machining of a flank of a tooth gap. It is thus a discontinuous method. Thus, for example, all concave flanks 5.1 of all teeth 5 are machined step-by-step (see FIG. 1A). Furthermore, a CNC controller 50 is shown, which is designed to control the movement sequences in the machine 20, as indicated by the control signals I1, I2.

(11) Furthermore, a computer 10 is shown, which is especially designed (programmed) to ascertain and/or calculate concentricity correction dimensions. The computer 10 is connected for communication to the machine 20 and/or the controller 50, as indicated in FIG. 2 by the connection 11. The computer 10 does not necessarily have to be embodied as a complete computer in various embodiments of the invention. A computer module, a chip module, or a plug-in card having processor or the like can also be used. The computer 10 can also be part of the controller 50, or the controller 50 can be part of the computer 10.

(12) FIG. 3 shows a perspective view of a second grinding machine 20 having a cup grinding wheel 2, which is arranged suspended, and which is mounted so it is rotatable on a tool spindle 21, and having a bevel gear workpiece 1 to be machined, which is mounted so it is rotatable on a workpiece spindle 22, wherein the cup grinding wheel 2 and the bevel gear workpiece 1 are not engaged at the moment shown. The statements that were previously made with reference to the computer 10 are also to be applied here.

(13) The single-spindle grinding machine 20 shown as an example in FIG. 3 furthermore comprises a tool carriage 23, which is mounted so it is displaceable on a machine stand 24 in parallel to the linear axis Y and the linear axis Z. The machine 20 has a further linear axis, which is referred to as the X axis. In addition, this machine 20 comprises a pivot axis C, which enables pivoting of the workpiece spindle 22 together with workpiece 1. In the example shown, the machine 20 has a collection region 25 for chips and a dressing unit 26 that can be used for the CNC-controlled dressing/profiling of the grinding tool 2. These components are optional. Furthermore, a CNC controller 50 is shown, which is designed to control the movement sequences in the machine 20, as indicated by the control signals I1, I2. A computer 10 can also be part of the controller 50, or the controller 50 can be part of a computer 10, in this embodiment.

(14) The machine 20 may be equipped with a tactile measuring sensor 30, as indicated in FIG. 3. The machine 20 can also comprise another measuring system (for example, an optical measuring system), however, which is designed to ascertain the concentricity error of the gear teeth by measurements on the re-chucked workpiece 1.

(15) The measuring system may be designed to sample or measure the tooth flanks (for example, the concave flanks 5.1), to ascertain the concentricity error on the re-chucked workpiece 1 therefrom or to ascertain (measurement) variables, which are correlated with the concentricity error.

(16) If a tactile measuring sensor 30 is used, it can thus be a scanning measuring sensor 30 or it can be a switching measuring sensor.

(17) The measuring system can be arranged on the machine 20 so that the measuring sensor 30 (or, for example, an optical sensor or a CCD element) is moved together with the main axes X, Y, Z of the machine 20.

(18) In some embodiments, the measuring system can be arranged on the machine 20 so that the measuring sensor 30 (or, for example, an optical sensor or a CCD element) has separate movement axes. In some embodiments, a combination is also possible, in which the measuring sensor 30 (or, for example, an optical sensor or a CCD element) partially has separate movement axes and is partially oriented to the main axes of the machine 20.

(19) The machine 20 may be equipped with a precision measuring instrument as a measuring system.

(20) The single-spindle grinding machine 20 of FIG. 3 is especially designed for grinding spiral-toothed bevel gears.

(21) FIG. 4A shows a graphic illustration of the total deviation of the tooth gaps of a bevel gear, wherein the deviations of the convex flanks 5.2 are shown on top and the deviations of the concave flanks 5.1 are shown on the bottom in the illustration. MI represents the center line. This total deviation was ascertained by means of a measuring system on a workpiece, which was subjected in a first chucking in a machine to a first single-indexing grinding procedure. In the scope of the first single-indexing grinding procedure, all convex flanks 5.2 of the workpiece were machined step-by-step here. After removal of the workpiece from the machine and after re-chucking of the workpiece in the machine, all concave flanks 5.1 of the workpiece were subjected to a second single-indexing grinding procedure. In the scope of this second single-indexing grinding procedure, all concave flanks 5.1 of the workpiece were machined step-by-step here.

(22) In this example, no adaptation of the concentricity error was performed.

(23) FIG. 4B shows a graphic illustration of two curve sequences K1, K2, wherein the curve sequence K2 of the convex flanks 5.2 is shown on top and the curve sequence K1 of the concave flanks 5.1 is shown on the bottom in the illustration. The center line MI and the location/the profile of the two curve sequences K1, K2 were taken from FIG. 4A.

(24) The two curve sequences K1, K2, or the concentricity error curves, respectively, have the profile of a periodic curve or they can be derived, for example, from a sine curve. It can be inferred from FIG. 4B that the phasing of the curve sequence K1 is shifted in relation to the phasing of the curve sequence K2. This results from the fact that the concentricity error in the first chucking of the workpiece is different from the concentricity error of the workpiece in the second re-chucking. The exactly identical concentricity error will be predefined upon the re-chucking as in the first chucking only in a few cases.

(25) Two tooth gaps 6.1 and 6.2 are shown as examples in FIG. 4B. The length of the respective line sections corresponds to the gap width of the respective tooth gaps 6.1, 6.2. Because the two curve sequences K1, K2 do not run in phase, in an unfavorable case, as shown in FIGS. 4A and 4B, a large variation of the gap widths can result. Such variations of the gap width, or the tooth thickness, which has a direct relationship thereto, is not acceptable for many applications.

(26) It is to be noted that the illustrations of FIGS. 4A to 5B are exaggerated. They only show the respective deviations with respect to the center line MI.

(27) FIG. 5A shows a graphic illustration of the total deviation of the tooth gaps of a bevel gear 1. The deviations of the convex flanks 5.2 are shown on top and the deviations of the concave flanks 5.1 are shown on the bottom in the illustration. The total deviation was ascertained by means of a measuring system on a workpiece 1, which was subjected in a first chucking in a machine 20 to a first single-indexing grinding procedure. In the scope of the first single-indexing grinding procedure, all convex flanks 5.2 of the workpiece 1 were machined step-by-step here. After removal of the workpiece 1 from the machine 20 and after re-chucking of the workpiece 1 in the machine 20, all concave flanks 5.1 of the workpiece 1 were subjected to a second single-indexing grinding procedure. Previously, however, a measurement of the concentricity error or of (measured) dimensions, which are correlated with the concentricity error, was performed by a measuring system of the machine 20.

(28) According to some embodiments, this measurement is performed after the re-chucking of the workpiece 1 on those flanks of the workpiece 1 that were machined in the scope of the first single-indexing grinding procedure.

(29) After concentricity correction dimensions for this workpiece 1 were ascertained by computer (e.g., in a computer-controlled manner), the CNC-controlled performance of the second single-indexing grinding procedure was performed using the second grinding tool. In the scope of the second single-indexing grinding procedure, all second tooth flanks of the first workpiece 1 were machined by grinding step-by-step, and adaptations of the machining movements of the second single-indexing grinding procedure were performed in this case on the basis of the concentricity correction dimensions.

(30) FIG. 5B shows a graphic illustration of two curve sequences K1, K2, or concentricity error curves, respectively, wherein the curve sequence K2 of the convex flanks 5.2 is shown on top and the curve sequence K1 of the concave flanks 5.1 is shown on the bottom in the illustration. The center line MI and the location of the two curve sequences K1, K2 were taken from FIG. 5A.

(31) The two curve sequences K1, K2 again have the profile of a periodic curve (they can be derived, for example, from a sinusoidal curve). It can be inferred from FIG. 5B that the phasing of the curve sequence K1 is hardly shifted in relation to the phasing of the curve sequence K2. The two curve sequences of FIG. 5B have nearly identical phasing.

(32) Two tooth gaps 6.1 and 6.2 are shown as examples in FIG. 5B. Because the two curve sequences K1, K2 run in phase or essentially in phase, the gap widths no longer deviate significantly from one another.

(33) It is possible to show on the basis of this example that bevel gears can also be machined by grinding, or using a machine 20 that is designed/programmed, respectively, so that in spite of the chucking and the re-chucking, they are comparable to gearwheels that were ground in a conventional manner on a dual-spindle grinding machine.

(34) As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, numerous changes and modifications may be made to the above-described and other embodiments of the present invention without departing from the spirit of the invention as defined in the claims. Accordingly, this detailed description of embodiments is to be taken in an illustrative, as opposed to a limiting sense.