Method and device for measuring a hobbing tool.

专利摘要:
In a method for measuring a tool (1) for the rolling machining of toothed workpieces, a virtual contact point is calculated on a rounded virtual cutting edge of a virtual tool. Then, the relative orientation between the tool axis (B) and the measuring device (11) as well as a translational relative position between the tool and the measuring device are calculated and set on the basis of the calculated virtual contact point. The measurement on the real cutting edge takes place in the set relative orientation and relative position. In particular, it can take place with the aid of a cylindrical feeler in the form of a light beam, wherein the cylindrical feeler touches the virtual cutting edge tangentially in the virtual contact point.
公开号:CH714443A1
申请号:CH01526/17
申请日:2017-12-15
公开日:2019-06-28
发明作者:Huber Philippe；Kirsch Roger；Marx Hartmut；Mros Michael；Müller Michel
申请人:Reishauer Ag；
IPC主号:

专利说明:

description
TECHNICAL FIELD The present invention relates to a method for measuring a rolling machining tool and an apparatus for carrying out the method.
PRIOR ART The skiving process is a continuous cutting process in which gear-like tools are used to machine rotating workpieces. In addition to soft machining, skiving can also be used for hard fine machining of pre-toothed workpieces. For workpiece machining, the tool and workpiece are held on rotary spindles. The axes of rotation of the tool and workpiece are skewed. By coupling the rotary movements of the tool and workpiece around the axes of rotation, the process-typical rolling movement is realized with a complicated skiving kinematics. With this cutting process, both external and internal gears can be machined.
The teeth of a skiving tool form cutting in the area of the end face of the tool. In practice, the cutting edge of each tooth does not form an arbitrarily sharp edge, but is rounded off with a radius. The final tooth flank on the peeled workpiece is formed by forming an enveloping cut through the geometrically defined cutting edge of the hob peeling tool, with practically no chip being removed at the end of the hob peeling process and the contact between the tool and workpiece only occurring at certain points. In the course of the rolling movement, the corresponding contact point between the finished workpiece and the tool moves continuously along the rounded cutting edge. The skewed arrangement of the axes of rotation of the tool and the workpiece means that the point of contact not only travels lengthways along the cutting edge, but also changes its position transversely to the curvature of the cutting tooth curve. The contact points acting in the course of the rolling movement thus form a space curve on the cutting tooth rounding. The course of this space curve is determined by the design of the tool and setting parameters such as the relative orientation and position of the tool and workpiece. The space curve can be calculated from the design data.
The dissertations by Andreas Hühsam, "Modeling and experimental investigations of the skiving process", research report Volume 111, wbk Institute of the University of Karlsruhe, Shaker Verlag GmbH, 2002, pages 23-66 and Andreas Bechle, "Contribution to reliable processing in the high-performance manufacturing process », Research Report Volume 132, wbk Institute of the University of Karlsruhe, Shaker Verlag GmbH, 2006, pages 26-28, extensively discuss the modeling of skiving and the quality-compliant manufacture of a skiving tool as a crucial element of the skiving process. A kinematic model of gear skiving is painstakingly presented. With this approach, the complex cutting geometry of a skiving tool can be calculated. Bechle shows the schematic process for producing this skiving tool in Fig. 2-21 on page 28. The tool blank is finished by grinding. After the first grinding pass, the gear peeling wheel is measured on a measuring machine and the dimensional and shape accuracy are determined. Deviations from the nominal geometry are determined and eliminated by correcting the NC dressing process and re-profiling the grinding wheel. This cycle repeats itself until the size and shape are right.
In a measurement with a conventional measuring machine, however, it is not taken into account that the contact points on the cutting edge curve migrate along the space curve already mentioned in the course of the rolling movement. A conventional measuring machine is not able to take this space curve into account.
In addition, a measurement on a separate measuring machine is disadvantageous because the reclamping of the tool between the measuring machine and the tool spindle is time-consuming and clamping and reclamping errors can occur which have a negative effect on the production result.
[0007] In US 2015/0 081 083 A1 it is proposed to measure a skiving tool by feel. For this purpose, a measuring body is provided which represents an exact image of the flanks of a workpiece toothing to be machined. Although this type of measurement enables a precise determination of the distance between the workpiece and tool axis to be set on the processing machine, it is not suitable for measuring the cutting edge that is used in skiving.
In WO 2016/150 985 A1 it is proposed to measure the deviation of the position of the head cutting edge, the left cutting edge and the right cutting edge of each cutting tooth of a gear peeling tool from an ideal contour, in order in this way to determine runout errors. The measurement is done with a measuring ball. With this method, the position of the cutting edge is determined, but the actual cutting edge itself is not measured. The determined positional deviations are then used during workpiece machining to reduce the effects of the concentricity error on the workpiece geometry by periodically nonlinearity of the coupling ratio between workpiece and tool rotation or a periodic change in the center distance is provided.
CH 714 443 A1 Methods for the optical measurement of measurement objects are known from the prior art which operate in the transmitted light method, i.e. the measurement object is placed between a light source and a light detector, and the light detector detects when the measurement object interrupts the light beam from the light source.
Such a method is e.g. disclosed in DE 19 927 872 A1. In order to be able to also detect areas that would otherwise be difficult to detect due to the geometry of the measurement object, it is proposed that the light source and the light detector form a unit and are attached to a swivel device. The pivoting device can be pivoted about an axis which intersects the axis of rotation of the measurement object. The swivel device is also translationally adjustable along a second axis running perpendicular to the swivel axis. The measurement object is adjustable along a third axis parallel to the first axis and rotatable about a fourth axis running parallel to the second axis and cut by the first axis. This makes it possible, e.g. with cutting teeth of a rotationally symmetrical tool to be measured behind the cutting edge. The document gives no suggestion to use such an arrangement for measuring skiving tools, in particular with rounded edges on the cutting edge.
[0011] EP 1 050 368 A1 proposes an optical measuring device for positioning devices. A light source and a light detector are arranged on a common holder and aligned so that a measurement light beam from the light source strikes the light detector. The light detector detects when the beam is interrupted by a measurement object. If an interruption occurs, a corresponding signal is generated. So there is a simple binary evaluation with the states «receive light» («L») and «no light received» («0»). The light beam can be uncollimated, i.e. it can easily diverge from the light source to the light sensor. A narrow light channel is arranged in front of the light detector, through which the light must pass in order to reach the light detector. As a result, the detector effectively “sees” only a cylindrical beam area of the light beam emanating from the light source. The light beam thus acts like a cylindrical scanning surface with which the measurement object is scanned. An application for the measurement of skiving tools is not disclosed.
A corresponding laser measuring bridge is z. B. under the name NC4 from the company Renishaw, Wottonunder-Edge, UK.
[0013] US 8 411 283 B1 discloses a method in which a gear wheel is measured by means of distance measurements. EP 1398 598 A1 proposes the measurement of a small cutting edge geometry using a line laser and image acquisition.
PRESENTATION OF THE INVENTION In a first aspect, it is an object of the present invention to provide a measuring method for measuring the cutting edge of a skiving tool, which enables measurement with particularly high precision, can be automated and can be implemented inexpensively, simply and quickly.
[0015] This object is achieved by a method having the features of claim 1. In addition, a measuring device for carrying out the method is specified with the features of claim 19. Further embodiments are specified in the dependent claims.
[0016] A method for measuring a tool for the rolling machining of toothed workpieces is therefore specified. The tool is rotatable about a tool axis and has a plurality of cutting teeth. Each of the cutting teeth forms at least one real cutting edge. The process is carried out using a measuring device. The method has the following steps, these steps not necessarily being carried out in the order given:
(a) calculating a virtual contact point on a virtual cutting edge of a virtual tool, the virtual cutting edge extending along a longitudinal direction of the cutting edge and having a rounding transverse to the longitudinal direction of the cutting edge;
(b) calculating a relative orientation between the tool axis and the measuring device and a translational relative position between the tool and the measuring device on the basis of the calculated virtual contact point;
(c) setting the calculated relative orientation between the tool axis and the measuring device and the calculated relative position between the tool and the measuring device; and (d) performing a measurement on the real cutting edge in the set relative orientation and relative position, the above steps (a) to (d) being carried out for a plurality of virtual contact points along the virtual cutting edge.
[0017] A virtual tool that defines a virtual cutting edge is therefore considered first. As can be seen from the description below, the virtual cutting edge is used to calculate how the tool axis should be aligned relative to the measuring device and how the tool should be positioned relative to the measuring device so that the
CH 714 443 A1
Measurement can be done with high precision. The virtual cutting edge corresponds to a predetermined cutting edge geometry, in particular the target cutting edge geometry according to the tool design. This virtual cutting edge does not form an infinitely sharp edge along the longitudinal direction of the cutting edge, but is rounded between the rake face or, if available, the rake face and free face or, if available, the free face chamfer. The virtual cutting edge thus forms a complex curved surface.
On this virtual cutting edge there is a space curve, which consists of the points at which the complex curved surface would touch a virtual workpiece with a predetermined nominal flank geometry if the virtual tool carries out the rolling movement with the virtual workpiece, as is also the case with the real machining of a real workpiece takes place with the real tool. These points on the virtual cutting edge are called virtual touch points. The curve of virtual contact points usually does not run in a face cut plane of the tool. The points in space, relative to the axis of the virtual workpiece and the axis of the virtual tool, at which this contact takes place across all rolling positions, also form a curve called the virtual line of engagement. The point on the virtual line of intervention belonging to a virtual contact point is referred to as a virtual point of intervention. The virtual point of contact on the cutting edge and the associated virtual point of engagement in space are identical in the event that you are in the rolling position in which the virtual point of contact touches the final contour of the workpiece target flank. There is also a virtual contact point on the virtual workpiece, which corresponds to the target geometry, which also coincides with the virtual engagement point in the contact rolling position.
For a selected virtual contact point it is now determined how the tool axis and the measuring device must be oriented relative to each other, and how the tool and the measuring device must be adjusted relative to each other with regard to their translational position, so that a measurement in the virtual contact point with the measuring device (and not somewhere else on the cutting curve). The orientation and translational position calculated in this way will generally change from virtual contact point to virtual contact point along the virtual cutting edge, in particular for a skiving tool due to the skewed arrangement between the virtual tool and the virtual workpiece.
[0020] The real tool and the measuring device are now set relative to one another as previously calculated. CNC axes of the machine are preferably used for this setting. In the orientation of the tool axis relative to the measuring device and the position of the tool relative to the measuring device set in this way, a measurement is then carried out on the real cutting edge of the real tool. If the cutting edge geometry of the real tool differs from that of the virtual tool in the calculated virtual touch point, the measurement quantifies the deviation at the virtual touch point. In particular, a further relative movement of the tool relative to the measuring device can be carried out to carry out the measurement; e.g. To carry out the measurement, the real tool can be rotated around the tool axis and the deviation can be expressed as a difference in the angle of rotation by which the real tool has to be rotated so that the real cutting edge and the virtual cutting edge coincide in the virtual contact point.
The above steps can then be repeated for one or more additional virtual touch points along the virtual cutting edge. In this way, the cutting edge is measured at several points along its longitudinal direction. In particular, the above-mentioned steps (a) to (d) can be carried out for at least five virtual contact points along the virtual cutting edge in order to enable a sufficiently detailed statement about the real cutting edge geometry.
In order to interpolate between the measured values for virtual contact points on the cutting edge, a compensation curve for the description of the real cutting edge can be calculated in a manner known per se from the measurement results which were determined for different contact points on the same cutting edge.
In order to adjust the relative orientation between the tool axis and the measuring device, it is fundamentally conceivable to change the orientation and position of the measuring device in space, while the orientation of the tool axis and the position of the tool is fixed. Alternatively, it is conceivable to change the orientation of the tool axis and the position of the tool in space while the measuring device is stationary. Mixed forms are also possible. Most of the time, however, the necessary CNC axes already exist on a machine tool, which make it possible to change the orientation of the tool axis in space and to adjust the position of the tool in space. It is therefore advantageous if the measuring device is spatially fixed during the implementation of the method and the relative orientation and the relative position are set for the respective virtual contact point by changing the orientation of the tool axis in space and the position of the tool in space.
[0024] The proposed method can be used with a wide variety of measurement methods. However, it is particularly suitable for a measuring method in which the cutting edge of the tool is scanned tangentially. For this purpose, the measuring device can provide a non-contact or touch probe, and the relative orientation and the relative position are calculated and set in such a way that the probe touches the virtual cutting edge tangentially at the calculated virtual contact point. The feeler can be a touching, physical feeler (a real, permanently existing body), e.g. a tactile finger, or it can be a non-physical, non-physical probe, e.g. in the form of a light beam.
CH 714 443 A1 There are further advantages if the probe is cylindrical in shape and thereby defines a cylindrical probe surface, since the position of the tool along the cylinder axis of the probe is not important for the measurement. This facilitates the setting of the position of the tool and the measuring device relative to one another and simplifies the measuring process.
If the probe is of cylindrical shape, this defines a cylinder axis, and the cylindrical probe surface is at a distance from the cylinder axis which corresponds to the cylinder radius. In an advantageous embodiment, the relative orientation and the relative position are then calculated and set in such a way that the cylinder axis of the cylindrical probe means runs parallel to the tangential plane on the virtual cutting edge in the calculated virtual contact point, namely at a distance from this tangential plane that corresponds to the cylinder radius. The cylindrical touch surface thus contains the virtual contact point and lies there tangentially to the virtual cutting edge.
When using a cylindrical feeler in the manner mentioned above, the cylinder axis runs in a plane that is parallel to the tangential plane on the virtual cutting edge in the calculated virtual contact point. There is still a degree of freedom for the alignment of the cylinder axis within this plane. This orientation can advantageously be chosen such that the cylinder axis runs essentially along the flank direction of the virtual workpiece. This alignment of the cylindrical stylus reduces the risk of collisions with other tool areas in the case of a physical stylus. In the case of a probe in the form of a light beam, this alignment reduces the risk of the light beam being shadowed by other tool areas.
If the probe is formed by a light beam, the method can be carried out in a simple manner as follows: To carry out the measurement, the tool is set in the respectively set relative orientation of the tool axis and at the set relative position between tool and measuring device in step ( d) rotated about the tool axis, and during the rotation it is detected at which actual angle of rotation the light beam is interrupted by the cutting edge. This results in alternating signals «L» (light beam not interrupted, detector bright) and «0» (light beam interrupted, detector dark). On this basis, a deviation between the detected actual angle of rotation and a target angle of rotation calculated for the virtual cutting edge can be determined. This deviation is a direct measure of the deviation of the actual cutting edge geometry from the target cutting edge geometry. An advantage of the proposed method is that this deviation is not determined at any given or random location on the curvature of the cutting edge, but rather exactly at the point at which the workpiece and tool would finally touch if the tool had the specified target geometry. The measurement is therefore carried out at precisely those points that really matter during machining and at which the cutting edge should therefore be measured particularly precisely.
The measurement in step (d) can be carried out in the respectively set relative orientation and relative position for several or all cutting teeth of the tool, so that several or all cutting teeth successively interrupt the light beam and release it again. In this way, several cutting teeth can be measured quickly and efficiently at the relevant virtual contact points without having to change the relative orientation between the tool axis and the measuring device and the relative position between these measurements.
At least one of the following parameters can be determined from measurements on several or all cutting teeth:
- tool runout;
- cutting tooth center;
- middle of the tooth gap.
One of the following variables can be determined from measurements on one, several or all cutting teeth:
- at least one measure for the deviation of the profile of a flank made with the real cutting edge to a virtual flank made with the virtual cutting edge (in particular the target cutting edge) (e.g. profile shape errors, pitch errors);
- At least one measure of the change in the cutting edge during machining, for example due to wear. [0032] The method can also include at least the following steps:
(e) determining at least one setting for a machine control on the basis of a result of the measurements, the setting causing a relative position between the tool and a workpiece to be set for machining the workpiece; and (f) transferring the setting to the machine control.
In other words, based on the determined cutting edge geometry, the setting of the tool relative to the workpiece can be changed, e.g. compensate for the wear of the cutting edge.
The setting determined in step (e) can also be transferred to an external computer system which saves the settings at several points in time and processes them for resharpening the tool. The transfer can take place via standard interfaces.
CH 714 443 A1 The method can also include visualizing a result of the measurement on a screen, in particular on a screen of an operating panel of a CNC machine control.
The tool can in particular be a skiving tool or a shaping tool.
In particular in the case of a skiving tool, the method proposed here has particular advantages because the skewed arrangement of the axes of rotation of the tool and the workpiece and the quasi non-volatile, complex cutting geometry result in special features which are generally not adequately taken into account in conventional measuring methods.
In particular, the tool can be a skiving tool with variable rake faces, as described in Swiss patent application CH 01412/16 dated October 21, 2016. The disclosure of this patent application is incorporated herein by reference in its entirety.
The method can be carried out while the tool is on a tool spindle, with which the machining of workpieces also takes place. In other words, the method can be carried out directly on the machine with which the workpiece machining also takes place. It is therefore not necessary to first clamp the tool onto the spindle of a separate measuring machine. However, it is also conceivable to carry out the method on a separate measuring machine.
Before the actual measuring method is carried out, additional method steps for calibrating the measuring position in the machine can be carried out. Such calibration steps can be repeated if necessary during a machining cycle.
An apparatus for performing such a method can have:
a tool spindle for driving the tool to rotate about the tool axis;
- the measuring device already mentioned;
- At least one driven swivel axis in order to change the relative orientation between the tool axis and the measuring device; and
- At least one driven linear axis to change the translational relative position between the tool and the measuring device.
The device then also has a controller which is designed to carry out the method shown above. The considerations given above regarding the method also apply to the device according to the invention. The controller can in particular have software which, when executed by a processor of the controller, causes the controller to carry out the method described above.
The device can have more than one pivot axis in order to be able to freely set the orientation of the tool axis in space relative to the measuring device. In this case, the pivot axes are preferably not parallel to one another and are preferably orthogonal to one another. The device can accordingly also have more than one linear axis in order to freely change the translational relative position between the tool and the measuring device. The directions of the two or three linear axes are then preferably linearly independent in the mathematical sense and preferably also orthogonal to one another.
[0044] In particular, the arrangement of the swivel and linear axes can be carried out according to the following rules:
- The measuring device is arranged stationary on the machine bed, and the tool is aligned and positioned in space by means of at least one linear axis and by means of at least one swivel axis; or
- The measuring device is fixedly arranged on a displaceable slide, which can be displaced at least along a linear axis, and the tool is aligned and positioned in space by means of at least one pivot axis.
In both variants, additional swivel and / or linear axes can be provided for the tool and / or for the measuring device.
In particular, a gear skiving head can be arranged instead of a grinding head on the tool carrier of a known gear cutting machine according to a machine concept according to US 6 565 418 B1 or according to US 5 857 894. The measuring device can be arranged in these machines as follows:
(i) In the machine concept of the gear cutting machine according to US Pat. No. 6,565,418 B1, a gear skiving head is arranged on a tool carrier, which can be moved relative to the machine bed. The machine bed also carries a movable, in particular displaceable or pivotable, workpiece holder. The measuring device can then be arranged on this workpiece carrier and can be moved from a parking position into a measuring position by means of this movable workpiece carrier. In this machine concept, the movable tool holder with skiving head implements three linear axes X, Y and Z as well as a swivel axis A and a rotation axis B. In addition, there is another linear or swivel axis C * that moves the workpiece holder with the measuring device from the park position to the measuring position and moved back. The movable workpiece carrier can serve other purposes. In particular, at least one workpiece spindle for clamping a workpiece to be machined can also be arranged on the movable carrier.
(ii) In the machine concept according to US Pat. No. 5,857,894, the gear skiving head is arranged on a tool carrier which can be displaced and pivoted relative to the machine bed. The machine bed also carries a stationary workpiece6
CH 714 443 A1 carrier with workpiece spindle. The measuring device can then be arranged in a stationary manner on this machine bed. In this machine concept, the movable tool carrier with skiving head also realizes three linear axes X, Y and Z as well as a swivel axis A and a rotation axis B. In addition, there is also another linear or swivel axis C *; but this serves to pivot the tool carrier (and not, as in the machine concept described above, the workpiece carrier). In this case, the tool carrier can preferably be moved, in particular pivoted, between a working position in which a tool attached to the tool spindle can be brought into engagement with a workpiece, and a measuring position in which the tool interacts with the measuring device.
As has already been stated, the measuring device can provide a touch-free or touch-sensitive probe, and the control can calculate and set the relative orientation and the relative coordinates such that the probe touches the virtual cutting edge tangentially in the calculated virtual contact point. As mentioned, it is advantageous if the feeler is cylindrical.
[0048] The measuring device can in particular form a light barrier. For this purpose, the measuring device can have a light source and a light detector, the light source being designed to generate a light beam which is aligned with the light detector. In this case, the probe acts without contact and is formed by at least one area of the light beam. The light source and the light detector are preferably configured in such a way that a cylindrical beam region of the light beam effectively acts as a scanning means. The control interacts with the tool spindle in such a way that the tool spindle rotates the tool for carrying out the measurement in the set relative orientation of the tool axis and at the set relative coordinates about the tool axis. The light detector is then designed to detect during the rotation at which actual angle of rotation the light beam is interrupted by the cutting edge. The light source can in particular comprise a laser, so that the measuring device forms a laser bridge. In particular, the laser can generate a beam of circular cylindrical shape.
BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention are described below with reference to the drawings, which serve only for explanation and are not to be interpreted as restrictive. The drawings show:
Fig. 1
Fig. 1a Fig. 2nd
Fig. 3
Fig. 3a Fig. 3b Fig. 3c Fig. 3d Fig. 3e Fig. 4
Fig. 4a
Fig. 5
FIG. 5a FIG. 5b FIG. 6 shows a perspective view of a workpiece and tool assignment with a skiving tool as well as a measuring device and further components of a skiving machine; an enlarged detail view of Figure 1 in the area DI.
a perspective view of a cutting tooth of a skiving tool with a vertical axis position of the tool spindle, wherein axially parallel cylindrical contact surfaces rest in fixed orientation on the cutting edge;
a perspective view of a cutting tooth of a skiving tool in a skewed axial position (analogous to the axis position during machining), cylindrical contact surfaces resting in different orientations on the cutting edge;
an enlarged sectional view in level S1 of Figure 3 in the contact point ml.
an enlarged sectional view in plane S2 of Figure 3 in the contact point m2.
an enlarged sectional view in level S3 of Figure 3 in the contact point m3.
an enlarged sectional view in plane S4 of Figure 3 in the contact point m4.
an enlarged sectional view in plane S5 of Figure 3 in the contact point m5.
a perspective view of a virtual workpiece in engagement with a virtual tool to illustrate the position of a cylindrical touch surface;
4 shows an enlarged detail view of FIG. 4 in the area D2, surface curves being entered for a better representation of a curved tooth flank;
3 another perspective view of a cutting tooth according to FIG. 3 with five measuring tracks and associated cylindrical tactile surfaces in the contact points on the effective cutting edge; a side view of a cutting tooth of Figure 5 with associated Z values of the five contact points. a plan view of a cutting tooth of Figure 5 with five measurement tracks and associated angular positions. another perspective view of a cutting tooth according to FIGS. 3 and 5;
CH 714 443 A1
Fig. 6a a schematic sectional view in level S1 of Figure 6 in a slanted axis position (analogous to the axis position during machining). Fig. 6b a schematic sectional view in level S1 of Figure 6 with tangential laser beam in the contact point m1 in a vertical position. Fig. 6c is a schematic sectional view in level S5 of Figure 6 in a slanted axis position (analogous to the axis position when machining); Fig. 6d a schematic sectional view in plane S5 of Figure 6 with tangential laser beam in the contact point m5 in a vertical position. Fig. 7 a perspective view of a vertically arranged laser bridge when testing a skiving tool and schematic representation of a corresponding L / 0 signal band; Fig. 7a an enlarged detail view of Figure 7 in area D3, L and 0 signals and the concentricity of the tool are shown schematically. Fig. 8 a diagram for the schematic representation of the measured values at the virtual contact points of a gear skiving tool, for example, with 75 cutting teeth, actual values, calculated compensation curve, cutting tooth center, tooth pitch and a tolerance range being shown schematically; Fig. 9 a side view of an arrangement with a vertically arranged laser bridge and tool spindle; Fig. 9a a perspective view of Figure 9 with rotation and linear axes for measurement. Fig. 10 a side view of an arrangement with tilted laser bridge and tool spindle; Fig. 10a a perspective view of FIG. 10; Fig. 11 a perspective view of an arrangement with a scanning and tactile button; Fig. 11a an enlarged detail view of Figure 11 in the area D4. Fig. 12 a perspective view of a gear cutting machine for skiving with a skiving head on a displaceable tool carrier and with two workpiece spindles on a pivotable workpiece carrier, the workpiece carrier carrying the measuring device; Fig. 12a an enlarged detail view of Figure 12 in the area D5. Fig. 13 a perspective view of a gear cutting machine with a workpiece spindle for skiving with a skiving head on a displaceable and pivotable tool carrier, wherein a measuring device is fixedly arranged on a machine bed; 13a an enlarged detail view of Figure 13 in the area D6. Fig. 14 a perspective view for calibration with calibration mandrel and tilted laser bridge; 14a a front view of Figure 14 with axial positions in the Y direction. 14b a side view of Figure 14 with axial positions in the X direction. and Fig. 15 a perspective view of an arrangement for post-process measurement of the workpiece with a scanning, tactile probe.
DESCRIPTION OF PREFERRED EMBODIMENTS The terms and toothing geometries applicable to spur gears are defined in the standard DIN ISO 21771: 201408 and are understood in this document in accordance with this standard.
In the drawings, embodiments of the method according to the invention are each shown schematically and enlarged. In all figures, the same reference numerals are used for the same or similar surfaces, axes, angles or other elements. Virtual objects such as virtual tools, virtual workpieces etc. are designated with the letter «v», which is followed by the reference symbol for the corresponding real object. The descriptions of the figures are generally for the skiving of external gears. Analogous considerations apply to the skiving of internal gears.
CH 714 443 A1 [0052] Exemplary embodiments of the method according to the invention are explained below in particular with reference to a real gear peeling tool 1 and a virtual gear peeling tool 1v. The hobbing tool 1 or 1v is gear-shaped and has a large number of cutting teeth 14 (see, for example, FIG. 2), each of which forms a rounded cutting edge in the region of the end face of the tool. It is pointed out that this tool is shown in a highly simplified manner in the drawings. The following considerations can be used for any skiving tools, including those with stair grinding or other geometrical designs.
Figure 1 shows an exemplary perspective view of selected elements of a modern CNC skiving machine 22. To describe directions in the skiving machine, a rectangular coordinate system K is used which defines the directions X, Y and Z. The origin of the coordinate system lies in the center of the workpiece or the workpiece axis C. A CNC control 8 serves to control the machine axes A, B, C, X, Y and Z. A control panel 9 forms the interface for the operating personnel for the CNC control 8.
The machine defines a work space 20. It has a machine bed 6. In the present example, a workpiece spindle 4 is arranged on a CNC-controlled feed carriage 5 with a displacement in the Y direction. A workpiece 3 is clamped on the workpiece spindle 4 with the aid of a clamping means, not shown in the drawing. The workpiece spindle 4 is rotatable about a workpiece axis C, the workpiece axis running vertically in the present example. A centering probe 7 is used to contactlessly determine the angular position of the tooth gaps of the workpiece 3 about the workpiece axis C in order to thread the workpiece 3 into the hobbing tool 1 without collision.
The hob peeling tool 1 is mounted on a tool spindle 2 and rotatable about a tool axis B. The tool axis B can also be wasted with the axis A by a tool setting angle 2 with respect to the vertical, the pivot axis A running parallel to the X axis in the present example. For this purpose, the machine 22 can have, in a known manner, a tool carrier (not shown in the drawing) with a pivoting body pivotally attached, to which the tool spindle 2 is in turn attached. The tool spindle 2 can be displaced along the directions X and Z with respect to the machine bed 6 by means of a slide (not shown in the following). Alternatively, if the CNC skiving machine 22 is equipped with a stationary workpiece spindle 4, then the tool spindle 2 can also be displaced in the Y direction.
The machine 22 also has a laser bridge 11. The laser bridge comprises a light source in the form of a laser, which generates a laser beam running vertically (in the Z direction), and a light detector, which detects an interruption of the laser beam by an object. The laser beam runs at a distance from the workpiece axis C, the laser beam being spaced from the workpiece axis C by an amount xm along the X axis and an amount ym along the Y axis. In the present example, the laser bridge 11 is fixed on the displaceable feed carriage 5 on the machine bed 6. All movements required for measurement are carried out by the rotary and translatory machine axes A, B, X, Y and Z. In particular, the tool spindle 2 is moved along the translatory axes X and Z from the axis position for machining the workpiece 3 and is brought into a suitable orientation by pivoting about the pivot axis A into an angular position Σ1. The spaced laser bridge 11 is then moved into an axial position for measuring the skiving tool 1 by moving the Y-slide 5. If the laser bridge 11 is alternatively fixed on the machine bed 6, then all translatory axes X, Y and Z are assigned to the tool spindle 2.
In a very simplified embodiment of this fixed arrangement of the laser bridge 11, only one linear axis could be used for the linear positioning of the tool 1. The X axis would move the tool 1 away from the workpiece 3 into the axis position for measurement. The Z axis would not be absolutely necessary when using a laser bridge 11 with a cylindrical laser beam 12, but would cause accuracy disadvantages if it were omitted. On the other hand, doing without the Y axis would partially limit the measurement procedure described below.
The relative positioning and alignment of measuring bridge 11 and tool 1 can also be realized in a different way than described above.
In addition, a virtual tool 1v is shown in FIG. 1 with the measuring position Mp. The meaning of the virtual tool 1v is explained in more detail below in connection with FIG. 1a.
1 a shows an enlarged detailed view of the laser bridge 11 in the area D1 with the skewed virtual tool 1v and with a virtual workpiece 3v, which is in meshing engagement with the virtual skiving tool 1v. Several reference planes Mxy, Mxz, Myz and Bxy are also shown in FIG. 1a. The reference planes Mxy, Mxz, Myz define the position and orientation of the laser bridge 11. In particular, the reference plane Mxz in the present example contains the laser beam 12 and runs through the housing of the laser bridge. The reference plane Myz also contains the laser beam 12 and is orthogonal to the reference plane Mxy. The reference plane Mxy runs horizontally and orthogonally to the two vertical reference planes Mxz and Myz. It defines the center of the laser bridge. The measuring position Mp is at the common intersection of the planes Mxy, Mxz, Myz. The reference plane Bxy runs orthogonal to the tool axis B and represents an end cut plane of the virtual tool 1v, this end cut plane running through the cutting edges of the virtual tool 1v.
[0061] The virtual tool 1v and the virtual workpiece 3v are in meshing engagement with one another. The virtual workpiece 3v has a predetermined target flank geometry. The virtual tool 1v has a variety of virtual ones
CH 714 443 A1
Cutting teeth, as shown by way of example in FIGS. 2, 3, 5 and 6. Each cutting tooth defines a rounded virtual cutting edge. This virtual cutting edge is designed in such a way that it generates precisely the predetermined target flank geometry of the workpiece 3v through the rolling movement of the tool 1v with the workpiece 3v. The virtual tool 1v and the virtual workpiece 3v touch each other on any given flank at any point in time of the rolling movement at most in a single virtual contact point. In the course of the rolling movement, the contact moves from contact point to contact point on the rounded cutting edge from the tooth base to the tooth head of the cutting tooth or vice versa. Due to the rotary movement of the virtual tool 1v, the virtual line of engagement describes a complex space curve. The position of a virtual point of intervention in space can easily be calculated as a function of the virtual contact point of the virtual tool 1v considered, if the tool design is known.
The virtual workpiece 3v and the virtual tool 1v are aligned and positioned in FIG. 1a such that the laser beam 12 is aligned essentially parallel to one of the flanks of the virtual workpiece 3v along its helix angle and precisely through the virtual point of engagement runs, namely in the rolling position in which a virtual contact point of the virtual tool 1v touches the virtual workpiece 3v and coincides with the virtual engagement point. The laser beam 12 thus runs in FIG. 1a through a point on the cutting edge of the virtual tool 1v, in which this cutting edge touches the flank of the virtual workpiece 3v, tangentially to the flank of the virtual workpiece 3v in its virtual contact point and tangential to the cutting edge of the virtual tool 1v in its virtual touch point. The necessary orientation and position of the virtual tool 1v depends on each virtual contact point along the cutting edge. Thus, a virtual contact point in the vicinity of the tooth base of the cutting tooth requires a different orientation and positioning of the virtual tool 1v than a virtual contact point in the vicinity of the tooth head. The required orientation and position of the virtual tool 1v can be easily calculated for each virtual contact point on the cutting edge.
For a measurement on the real tool 1, the real tool is now brought into exactly the position and orientation in which the virtual tool 1v is located in FIG. 1a. The real tool is now rotated about the tool axis B and it is observed at which angles of rotation the cutting teeth of the real tool interrupt the laser beam 12. If the cutting edge geometry of the real tool 1 does not match the cutting edge geometry of the virtual tool 1v at the selected contact point, the angles of rotation thus determined will deviate from those angles of rotation at which the virtual tool 1v would interrupt the laser beam. This deviation is a measure of the deviation of the real cutting edge geometry from the virtual cutting edge geometry in the selected virtual contact point.
This measurement is now repeated for further virtual contact points along the cutting edge of the virtual tool 1v.
During the measurement, the laser beam 12 describes a circular path in the reference plane Bxy when viewed from the rotating tool. The radius of the circular path depends on the virtual contact point on the cutting edge of the virtual tool 1v. The radius is smaller for a virtual contact point on the tooth base of the cutting tooth than for a virtual contact point on the tooth head. The corresponding circular path is referred to below as the measurement track. In Fig. 1a, one of these measurement tracks is drawn and given the designation R3. In practice, measurements are carried out for at least five measurement tracks with different radii, the contact points defining different radii of the corresponding measurement track. For each contact point or radius of a measuring track, the measurement is carried out in a different relative position between the tool 1 and the laser bridge 11. This position is chosen so that the measurement takes place at the point on the cutting edge at which the cutting edge is also at of the actual processing, namely at the point of contact during processing. This avoids measurement errors that would arise if the tool were simply always measured in the same orientation for different virtual contact points on the cutting edge. This is explained in more detail below with reference to FIGS. 2 and 3.
2 shows a single cutting tooth 14 of a gear skiving tool 1 with a vertical axis position B of the tool spindle 2, the cutting tooth being manufactured exactly according to the tool design. The cutting tooth 14 has a left cutting edge 28 and a right cutting edge 29. A rake face 19 is formed between rake face 18 and cutting edge. A method not according to the invention is explained with reference to FIG. 2, in which the measurements are carried out on the cutting edges without taking into account the course of the contact points over the cutting edges. In the method in FIG. 2, the measurement for all positions along the cutting edge is always carried out in the same relative orientation between tool 1 and laser beam 12. For this purpose, laser beam 12 in FIG. 2 is understood as a cylindrical scanning surface and depends on the relative position between tool 1 and laser beam referred to as T1 to T5. With this method, the cylindrical touch surfaces T1 to T5 are always parallel to the tool axis B, regardless of the position to be measured on the respective cutting edge. If the tool is now rotated through the laser beam, the laser beam or the touch surface describes a circular path R1 to R5 relative to the tool. The cutting edge 28 always interrupts the laser beam at its outermost edge, i.e. on the edge 16 to the adjacent open area, and only releases it again at its outermost edge. However, the point at which the cutting edge 28 interrupts the laser beam does not correspond to the actual contact point between the cutting edge and the workpiece during workpiece machining: the actual contact point is generally farther away from the open area on the rounded cutting edge because of the skewed arrangement of the tool and the workpiece lie. From Fig. 2 it can be seen that by
CH 714 443 A1 this deviation measurement errors can arise. Since the radius with which the cutting edge is rounded is usually in the micrometer range, measurement errors in the micrometer range result from this conventional method.
3 and FIGS. 3a to 3e, the method according to the invention is explained in more detail below. 3 again shows a cutting tooth 14 which was manufactured exactly according to the tool design, but in an orientation tilted by an angle Winkel. On the left cutting edge 28 (hereinafter also referred to simply as cutting edge S) of this tooth 14, contact points m1 to m5 are drawn, in which the cutting edge would touch the tooth flank of a finished workpiece during the workpiece machining, each of the contact points m1 to m5 being one corresponds to another pitch angle between tool and workpiece. The contact points m1 to m5 can be easily calculated from the tool design. They lie on a path that runs over the rounded cutting edge. The connection of these contact points m1 to m5 forms the compensation curve 17. It can be seen that this path deviates considerably from the edge 16 in FIG. 2.
The method in accordance with the invention takes this deviation into account. For this purpose, the tool axis is tilted for each contact point m1 to m5 by a different angle Σ with respect to the vertical, so that the laser beam 12 or the cylindrical touch surfaces T1 to T5 touch the cutting edge tangentially in the respective contact point m1 to m5. The required values of the angle S can also be easily calculated using the tool design. In this way, the geometry of the cutting edge along the path of the point of contact can be precisely measured. The following applies: The surface normal of the cutting edge is always perpendicular to the machined flank of the workpiece at the respective contact point m1 to m5, and the laser beam or the cylindrical touch surfaces T1 to T5 are always at right angles to this perpendicular.
3a to 3e schematically show, in enlarged sections in the planes S1 to S5, the geometric relationships at the contact points m1 to m5. In Fig. 3e, all reference numbers relevant here are represented as a representative of FIGS. 3a to 3d (contact point m5, radius r5, rake face 18, rake face 19, spatial movement path 24 of the contact point, lot 32 on the cutting edge). It can be seen how the position of the contact point m1 to m5 on the curvature changes from the contact point to the contact point, and how the tangential direction of the cylindrical touch surface T1 to T5 changes relative to the tool axis B. If the rounded right virtual cutting edge 29 is to be measured, a further measurement round on changed axis positions is carried out analogously.
4 and 4a, a virtual workpiece 3v is shown, which is processed by the virtual tool 1v. The virtual workpiece 3v corresponds to a workpiece finished with the virtual tool 1v. On the basis of this representation, the position of a cylindrical touch surface, here the touch surface T3 or the laser beam 12, is to be explained again in space. The tool axis B of the virtual tool 1v is pivoted into its measuring position by the angle Σ3. The right cutting edge 29 of the virtual tool 1v touches the curved tooth flank Cz of the virtual workpiece 3v at the contact point m3. The curvature is indicated by the surface curves 13. The tactile surface T3 or the laser beam 12 now runs such that the tactile surface T3 lies on the curved tooth flank Cz in the tangential plane Ct associated with the contact point m3 and in the flank direction, i.e. in the direction of the helix angle (indicated here by the angle β3).
5, 5a and 5b show different views of a cutting tooth 14 with five contact points m1 to m5, five associated measurement tracks R1 to R5 and five associated cylindrical tactile surfaces T1 to T5. 5 shows a perspective view analogous to FIG. 3. FIG. 5a shows the side view of this cutting tooth 14. It can be seen that the individual contact points m1 to m5 each have different positions Z1 to Z5 along the Z axis. So they are not in a common plane perpendicular to the Z axis. Therefore, the Z position of the tool must be changed for the measurements at the different contact points m1 to m5.
5b shows a plan view of the cutting tooth 14. If the skiving tool 1 with the cutting tooth 14 is moved past the cylindrical contact surface T1, for example on the measurement track R1, the angle of rotation φ1 can be determined at which the cutting edge touches the contact surface T1 in Touching point m1 touches by determining a 0 signal from the laser bridge. For the other measuring tracks R2 to R5, the rotation angles Φ2 to Φ5 are recorded analogously, the cylindrical sensing surfaces T2 to T5 each having a changed angular position relative to the tool axis B. The detection of these angles of rotation enables an exact image of the contact points on the cutting edge S.
6 again shows a perspective view of a cutting tooth 14 analogous to FIG. 3, only two contact points m1 and m5 with associated cutting planes S1 and S5 and associated tactile surfaces T1 and T5 being shown. The touch surfaces can in turn be realized by a laser beam 12. 6a to 6d schematically show sections through the cutting tooth 14 in the levels S1 and S5, the following explanations being valid:
6a shows in section S1 a section in the axis position for machining and FIG. 6b in the axis position for measuring the contact point m1.
FIG. 6c shows in section S5 a section in the axis position for processing and FIG. 6d in the axis position for measuring the contact point m5.
CH 714 443 A1
In the relevant axis arrangement for measuring, the cylindrical touch surfaces T1 and T5 are always spatially fixed and vertically arranged.
The existing machine axes are used to move the tool from the axis position for machining to the axis position for measuring the first contact point m1 and to align it relative to the cylindrical touch surface. For this purpose, the tool spindle 2 and, depending on the embodiment of the invention, also the workpiece spindle 4 moves to the measuring position Mp by means of the translatory axes X and Y. The tool spindle 2 is initially still in the original setting angle Σ Cutting tooth 14 brought into the center of the laser beam 12 at the level of the horizontal plane Mxy (see FIG. 1a). If necessary, the X and Y axes are used again. When aligning the axes for measuring, the tool spindle 2 pivots into the new setting angle Σ1 by means of the pivot axis A, the previous tool setting angle Σ being corrected by the helix angle β1 at the contact point m1. This results in a transformation of the setting values from the axis position for processing into the axis position for measuring at the selected contact point. After swiveling in on the tool component angle Σ1, the tool spindle 2 travels at least one full spindle revolution at a defined speed nB, and the angles of rotation Φ at which the laser beam is interrupted by the cutting edge are recorded. After the first measurement, the tool spindle 2 is moved into the axis position for measuring at the next contact point m2, and the process is repeated analogously until the measurement at the contact point m5. The order of these measurements can also be reversed. After measuring the contact points on one side of the cutting edge, the contact points on the other cutting edge are measured analogously. The same or a different direction of rotation of the tool spindle 2 can be used for this.
With a non-contact laser beam 12, spindle speeds nB greater than 60 rpm can be used without problems during measurement. This means that a complete measurement with at least five measurement tracks R1 to R5 can be carried out in less than 5 to 10 seconds. After five rounds of measurement, a sufficient number of measured values are normally recorded and stored in a table in the CNC control 8. These values can now be evaluated as required using methods customary in measurement technology. If necessary, the number of measuring rounds can be increased. In the above example, the laser beam 12 or the touch area T1 to T5 is arranged vertically. Instead, the laser beam can also have any other orientation in space. In the case of a differently arranged laser beam or a differently arranged tactile surface, the setting values are transformed analogously from the axis position for processing into the axis position for measuring, which is associated with the respective contact point to be measured.
7 shows a measuring device 11 with a vertical laser beam 12, a virtual skiving tool 1v with the contact point m3 being in the measuring position Mp. The virtual skiving tool 1v can also be understood here as a simplified representation of a real tool 1 in an end cut plane Bxy. The spindle axis B or the face cutting plane Bxy are swiveled in by the previously described tool setting angle zuvor3. The measuring position Mp lies in the fixed intersection of the planes Mxy, Mxz and Myz. Also shown is a virtual workpiece 3v which is in meshing engagement with the virtual skiving tool 1v, the laser beam 12 tangentially touching the tooth flank Cz at the common contact point m3. This virtual workpiece 3v is shown purely for visual explanation.
The virtual skiving tool 1v rotates past the laser beam 12 at the spindle speed nB, an L signal 26 and a 0 signal 27 alternatingly being generated per cutting tooth 14. The cutting tooth 14 interrupts the laser beam 12, a 0 signal 27 being generated. In the tooth gap, this laser beam 12 is released again and an L signal 26 is generated. Both the L signal 26 and the 0 signal 27, the corresponding angular position of the CNC tool spindle B is detected. It should be noted that only the 0 signals 27 are evaluated in the first round of measurement, for example for the right cutting edge 29, and are stored in a table in the CNC control 8. In the second round of measurement, with the same direction of rotation of the tool spindle B, but with a changed axis position for the left cutting edge 28, only the L signals are evaluated and likewise stored in a table. The measurement values are assigned to each measurement track in the CNC control 8, and a possible final result is shown schematically in FIG. 8. On a first cutting tooth 14 pivoted away from the laser beam 12, it is further shown in FIG. 7 a that with this first measurement by means of L / O signals a first cutting tooth center 15 in a skewed position can be defined. If this center 15 is used as a reference value, the following angular positions of the tool spindle B can refer to this value.
It may be sufficient to determine each individual cutting tooth center 15 only in one measuring track R3 and to form an average value therefrom. If this mean is within a defined tolerance range Δ, processing can start without hesitation. A measurement in only one measuring track can also be sufficient for the measurement of the concentricity R, the concentricity measurement being carried out analogously to the detection of the center of the cutting tooth. To determine the cutting shape of the cutting tooth 14, however, measurements in several, preferably at least five measuring tracks R1 to R5 are required.
The L / 0 signals on a tooth-shaped tool 1v can also be represented schematically as a linear L / O signal band 25. With 75 cutting teeth z1 to z75 on tool 1v, there are also 75 times L and 0 signals. The measured deviations can thus be visualized very well, in particular on the screen of an operating panel 9.
CH 714 443 A1 [0080] FIG. 7a shows an enlarged detail view in the area D3 at the contact point m3. In this view, the cutting edges 28, 29, 30 and 31 are shown by way of example. Also shown: virtual tool 1v, laser beam 12, cutting tooth 14, incisor center 15 in a skewed position, L and O signals 26, 27, contact point m3, measuring position Mp, concentricity R, measuring track R3 and pitch angle τ.
8, the angular positions Φ of the L / O signals for each measurement track R1 to R5 are shown schematically. As already mentioned, these angular positions can be stored in the CNC control 8, displayed on the screen of the control panel 9 and used for a wide variety of measurement tasks as required. Using standard mathematical methods for compensation calculation, the method of least squares e.g. the concentricity R, the cutting tooth center 15 and / or the pitch angle τ can be determined relatively easily and quickly. To measure the spatial cutting edges S, several, preferably at least five, measuring tracks R1 to R5 are traversed. The geometry of the cutting edge S with the compensation curve 17 can then also be determined from the measured values using the method of least squares. A comparison with a previously calculated ideal cutting edge 21 is then possible. To check the measurement results, another measurement track can be traversed in the shortest possible time. Prescribed tolerance bands (tolerance range Δ) are shown in dashed lines.
9, 9a, 10 and 10a illustrate that the laser bridge 11 does not necessarily have to be aligned vertically. 9 and 9a, the laser bridge is aligned as described above in such a way that the laser beam 12 runs vertically, parallel to the Z axis. If the laser beam 12 is exactly cylindrical, or if the area of the laser beam 12 that is effective during the measurement is of exactly cylindrical shape, the exact position of the workpiece plays with this arrangement
I don't matter along the Z axis. Exact positioning in the Z direction is therefore not necessary. In particular, the tool 1 for the measurement does not necessarily have to be in the reference plane Mxy of FIG. 1a. In the Fig.
and 10a, on the other hand, the laser bridge 11 is tilted from the vertical around the Y axis with the angle δ. The risk of a collision of the laser bridge 11 with the tool holder or tool shank of the tool spindle 2 is thereby reduced. However, the laser beam 12 no longer runs parallel to the Z axis. The tool spindle 2 must therefore be positioned with respect to the Z direction during the measurement such that the contact point to be measured is located on the virtual cutting edge in the reference plane Mxy. With this alignment of the laser beam 12, an exact positioning of the tool along the Z direction is required.
11 shows alternatively a measurement of a skiving tool 1v by means of a tactile probe 23. The cutting tooth 14 is preferably scanned. Because of the touching measurement, free rotation of the skiving tool 1v is not possible during the measurement. During the scanning process, the CNC axes A, B and X move synchronously and relatively slowly. The Z axis does not necessarily have to be traversed. If necessary, the Y axis can also be activated synchronously. In practice, corresponding measurement curves 21 can be measured on at least three cutting teeth 14. The button 23 also uses a cylindrical stylus with a cylindrical tactile surface T1.
11a shows the engagement of the cylindrical tactile surface T1 of the tactile probe 23 on the cutting tooth 14 to be scanned in the area D4 of FIG. 11. During this scanning, the cylindrical touch surface T1 of the tactile probe 23 is also used tangentially on the rounded cutting edge S of the skiving tool 1v. Here, however, scanned measured values 21 are generated instead of the L / 0 signals, which are related to the associated angular position Φ about the tool axis B.
12 and 13 show possible arrangements of the laser bridge 11 on skiving machines, which are built on the platform of traditional gear cutting machines.
12 illustrates a variant of a skiving machine in which the measuring device is in the form of a laser bridge
II is arranged on a movable carrier in the form of a workpiece carrier 33. The workpiece carrier 33 can be pivoted about a vertical axis C * into several positions. A machine concept with such a movable workpiece carrier is disclosed in US 6 565 418 B1. A workpiece spindle 4 is offset with respect to the pivoting direction (offset by 90 ° in the present example) to the laser bridge 11 likewise on the workpiece carrier 33. By pivoting this workpiece holder about the axis C *, the workpiece spindle 4 or the laser bridge can be brought into a position in which it interacts with the tool 1. The workpiece carrier can carry a second workpiece spindle (not shown in the drawing), which is arranged offset by 180 ° to the first workpiece spindle. In the illustration in FIG. 12, this second workpiece spindle is located on the rear side of this workpiece carrier. In this way, machining can take place on one of the workpiece spindles, while on the other workpiece spindle a finished workpiece can be replaced by a workpiece to be newly machined. This avoids unproductive idle times. In this machine concept, the tool spindle 2 is accommodated in a movable roller peeling head 35 which is arranged on the tool carrier 34 and is displaceably located on a machine bed 6.
12a shows an enlarged detail from FIG. 12 in area D5. As can be seen from this detail, in the present example the laser beam 12 of the laser bridge 11 is not oriented vertically, but is preferably at a tilt angle δ to the vertical. This ensures that the laser bridge 11 can remain within the contour of the workpiece carrier 33, thereby making it easier to seal the working space.
CH 714 443 A1 Another variant of a gear peeling machine is shown in FIG. 13. This hob peeling machine is based on a machine concept as disclosed in US Pat. No. 5,857,894. In this embodiment, the laser bridge 11 is arranged stationary on a machine bed 6, and the movements required for measuring are carried out by a displaceable and pivotable tool carrier 34. In this machine concept, the tool spindle 2 is accommodated in a movable roller peeling head 35, which is arranged on this tool carrier 34, which is located on a machine bed 6. The tool carrier 34 can be pivoted about a vertical axis C * between a machining position, not shown, and the measuring position shown in FIG. 13. In the machining position, the tool 1 is arranged such that it can interact with the workpiece 3 in order to machine it. In contrast, in the measuring position, the tool 1 is arranged such that it can interact with a measuring device in the form of a laser bridge 11. In the present example, the swivel angle between the machining position and the measuring position is 180 °. Of course, other swivel angles are also conceivable.
FIG. 13a shows an enlarged detail from FIG. 13 in the area D6. As can be seen from this detail, the laser beam 12 of the laser bridge 11 is also not aligned vertically in the present example, but is at an angle δ to the vertical. However, a fixed, vertical arrangement of the laser bridge 11 is also conceivable.
Automated tool measurements in a gear cutting machine 22 for hard machining require high-precision relative movements between the described active pair of tool 1 and measuring device in measuring position Mp. The existing relative movements between the other active pair of tool 1 and workpiece 3 generally already have a high basic geometric accuracy in the micrometer range or for rotary axes in the range of arc seconds. In order to ensure a high-precision measurement in the working space of a skiving machine 22, the measuring position Mp should be automatically calibrated at the beginning of each processing and, if necessary, in between. A possible procedure for this is explained below with reference to FIGS. 14, 14a and 14b.
14 shows a calibration mandrel 36 in a gear skiving machine 22, not shown, with a coordinate system for the axes X, Y and Z. The calibration mandrel 36 with a defined height h (see FIG. 14a) and a defined calibration diameter 0D (see FIG. 14b) is picked up by the tool spindle 2 (not shown) and moved into the calibration plane EK at position Z1 *. The measuring position Mp of the laser bridge 11 is also in this plane. Thus, if the calibration mandrel 36 first starts from a suitable X position in FIG Laser beam 12, and this is hidden. This creates a 0 signal 27 in the laser bridge 11, which marks the Y position Y1 * .O in the CNC control 8. If the Y-axis continues, then the calibration diameter 0D releases the laser beam 12 and an L-signal 26 is generated analogously to the 0-signal 27, which marks the Y-position Y1 * .L in the CNC control 8. The center between the two Y positions is defined by means of CNC control 8 as the distance ym between laser beam 12 and workpiece axis C. However, this is not yet sufficient for the high-precision calibration of the measuring point Mp. The exact angular position ε of the laser beam 12 in the plane Y-Z must also be recorded or set.
Within the scope of the invention, the measurement of a skiving tool 1 could be carried out in any angular position ε, the vertical position of course preferably being used. Therefore, a second calibration step at a higher Z position Z2 * makes sense, whereby the Y positions Y2 * .O and Y2 * .L are marked and evaluated analogously. With even higher accuracy requirements, calibration steps can also be carried out in further Z positions. With these values, the CNC control 8 can determine the angular position ε with high precision. If the laser beam 12 does not intersect the calibration diameter 0D during this calibration in the Y direction, then it must be fed in in the X direction.
The next step in the calibration takes place in the X direction to determine the distance xm and the angular position 8, shown in FIG. 14b. Since the ym distance of the laser beam 12 from the workpiece axis C was determined in the preceding steps for calibrating, the Y axis with tool spindle 2 can move the rotationally symmetrical calibration mandrel 36 to this position. At the start, this tool spindle 2 is at the zero position of the X axis and at the Z1 'position of the calibration plane EK. The tool spindle 2 now advances the calibration mandrel 36 in the X direction until the calibration diameter 0D intersects the laser beam 12 and thereby generates a 0 signal 27 as described above, which in the CNC control 8 generates the X position X1'.O marked and thus defines the xm distance of the laser beam from the workpiece axis C. The tilting angle δ in the plane X-Z can be determined with an analog calibration process at height Z2 '.
After each calibration process, the calibrated distances ym and xm and the relevant angular positions δ and ε for the measuring position Mp can be stored in the CNC control 8 and used for further measurements.
However, the description of this calibration process also shows that a preferred measurement of the skiving tool 1 in the calibration plane EK is largely independent of angular errors and can therefore also be used advantageously with an exactly cylindrical laser beam 12.
15 illustrates an optional post-process measurement on the peeled workpiece 3 by means of a scanning probe 10, which can preferably be arranged on the tool spindle 2. This measurement takes place e.g. in at least three tooth gaps according to the conventional basic circle measurement. Based on the measurement results, if necessary
CH 714 443 A1 made further corrections to the setting values for workpiece machining. This enables optimal quality assurance to be achieved.
The tool is shown in a highly schematic manner in all of the present drawings. Furthermore, in the tool of the above drawings, the rake faces of all cutting teeth lie in a common plane. However, the above considerations are not limited to the tool shown, but can be used for any skiving tools, including those with step grinding or other geometric designs, or other gear-shaped tools.
[0098] Overall, the method proposed here enables the following advantages:
- Non-contact, fast and highly precise in-process measurement by means of laser bridge 11 at the beginning and during the machining of a workpiece lot, with all measured values being stored in the control.
- By continuously comparing the current measured values with the starting values, massive changes to the cutting edge can be recognized, for example wear V (see FIG. 6b).
- Direct detection of the spatially acting, rounded cutting edge S with the compensation curve 17, which generates and defines the final tooth flank on the peeled workpiece 3 during the skiving machining by its envelope cuts.
- When machining a series of workpieces, the time-consuming process of finding the appropriate setting values for the CNC axes of the gear skiving machine can be significantly reduced by precisely measuring the effective cutting edges, largely avoiding process-related rejects.
[0099] In summary, the method proposed here has the following special features:
- A cylindrical touch surface can be used for the measurement, which lies tangentially to the rounded cutting edge.
- The cylindrical touch surface is arranged such that it lies in the respective contact point on the curved tooth flank of the workpiece in the associated tangential plane and is preferably oriented in the direction of the corresponding helix angle.
- An exactly circular, cylindrical, high-precision laser beam is preferably used as the cylindrical touch surface. As an example of other forms of implementation of the invention, a tactile probe with a cylindrical probe can also be used. However, the long measuring times, the tactile scanning and the complex signal processing are disadvantageous here.
- The measuring laser beam therefore lies in the tangential plane of a corresponding contact point on the curved tooth flank of the workpiece and would have to be swiveled into the associated helix angle when measuring at other contact points. This selective helix angle on a tooth flank increases with increasing tooth height. The orientation of the laser beam and thus also the setting of a corresponding measuring device is determined by this helix angle and the tool setting angle, an adjustable angular range of approximately 0 to 90 ° being required for the laser beam.
In practice, however, it would be rather disadvantageous in terms of costs if the measuring device had to carry out these movements with the laser beam. The laser beam can therefore advantageously be arranged in a quasi-fixed and vertical manner in the working space of the skiving machine, and the adjustment of the alignment between the laser beam and the tool axis is instead implemented by the existing CNC swiveling device of the tool spindle. The linear infeeds of the existing CNC axes X, Y and Z can also be implemented accordingly. The machine settings must be calculated according to the measuring position. In addition, it is advantageous to arrange the quasi-fixed measuring position at a distance from the workpiece position, so that there is sufficient collision-free space for positioning the tool spindle with the tool.
- A fixed laser beam can then be used to scan several, preferably at least five, radial measuring tracks at a defined speed in the area of the tooth-shaped, rounded cutting edges on the rotating hob peeling tool, each measuring track being traversed at fixed values of the tool setting angle. The calculated contact point per flank is positioned in the measuring position on the laser beam by linear and rotary infeeds in the X, Y, Z, A and B axes. With the laser beam, the alternating interruption when turning the tooth-shaped tool very easily generates a safe and simple L / 0 signal. After measuring one side of the cutting edge, the other side of the cutting edge can be measured analogously, but with changed setting values.
- If a cutting tooth is moved past the tool on a measuring track past the laser beam, then it can easily recognize the contact point by means of an L / O signal, and the corresponding angle value of the rotating CNC tool spindle can be recorded. These angle values and the setting values for the radial measuring tracks can be saved in a table in the CNC control and then used for a wide variety of gearing-typical measurements.
The method proposed here was explained above using examples in which a cylindrical touch surface (e.g. in the form of a laser beam) scans the cutting edge tangentially. An important aspect was that a virtual contact point is calculated on a virtual cutting edge and the measurement is carried out in an orientation and translational position between the cutting edge and the measuring device, which depends on the position of the virtual contact point on the cutting edge. At least part of the advantages mentioned above can also be achieved by
CH 714 443 A1 a touch surface is used, which is not of cylindrical shape. For example, it is conceivable to use a laser beam that is focused on the point of contact. It is also conceivable to use a non-cylindrical physical probe, e.g. in the form of a ball.
At least some of the advantages mentioned can also be achieved by not performing a tangential scan, but measuring the cutting edge in another way, e.g. by distance measurements using triangulation methods or a 3D scan measurement. The method presented above is therefore not limited to tangential scanning using cylindrical touch surfaces.
REFERENCE SIGN LIST [0102]
Wälzschälwerkzeug
1v virtual skiving tool
tool spindle
Workpiece, gear wheel
3v virtual workpiece
Workpiece spindle
feed slide
machine bed
Einzentriersonde
CNC Control
Operator panel scanning probe
laser bridge
laser beam
face curves
cutting tooth
Cutting tooth center
Edge at the transition from the cutting edge radius to the free surface
regression curve
clamping surface
Spanflächenfase
Working area of a skiving machine scanned measurement curve, measured values
Gear skiving machine, gear cutting machine, tactile probe
Path of movement of a contact point
L / O signal band
L signal
0 signal
CH 714 443 A1
Cutting edge, left
Cutting edge, right
Cut on the foot
Cut your head
Lot on the cutting edge
Workpiece carrier
tool carrier
Wälzschälkopf
calibrating
cut blank
A Swivel axis of the tool spindle
B tool axis
Bxy tool reference plane in the face cut
C workpiece axis
Ct tangent plane at the point of contact of a tool with a workpiece
Cz tooth flank on the workpiece
C * swivel axis of the tool holder
C ** Swivel axis of the workpiece carrier
D1 to D6 detail areas in the figures
0D calibration diameter at the calibration dome
EK calibration level at position Z1 * h height on the calibration mandrel
K coordinate system of the machine with X and Y origin in the workpiece axis C
Mp measurement position
Mxz vertical plane through the center of the laser beam in the X direction;
Myz vertical plane through the center of the laser beam in the Y direction;
Mxy horizontal center plane of the laser bridge m1 to m5 virtual contact points on the cutting edge nB speed of the tool spindle
R Concentricity of the skiving tool
R1 to R5 radii of the measurement tracks on the skiving tool r1 to r5 radii on the cutting edge
S virtual cutting edge
S1 to S5 cutting surfaces on the cutting tooth, perpendicular to the rake surface and at right angles to the compensation curve T1 to T5 cylindrical contact surfaces that are tangent to a rounded cutting edge
CH 714 443 A1
V
X
X1 * .O
X2 * .O xm
Y
Y1 * .O
Y1 * .L
Y2 * .O
Y2 * .L ym
Z
Z1 *
Z2 *
Z1 to Z5 z1 to z75 ß1 to ß5 δ ε
Δ
Σ
Σ1 to Σ5 τ
Φ 1 to Φ 5
Wear on the cutting edge of the translatory CNC axis
X position when calibrating at calibration level EK
X position when calibrating to Z position Z2 *
X distance of the laser beam to the workpiece axis translational CNC axis
Y position when calibrating on calibration level EK with O signal on the laser bridge Y position when calibrating on calibration level EK with L signal on the laser bridge Y position when calibrating to Z position Z2 * with O signal on the laser bridge Y- Position when calibrating to Z position Z2 * with L signal at the laser bridge Y distance of the laser beam from the workpiece axis translational CNC axis
Z position when calibrating at calibration level EK
Z position during calibration; elevated
Z height of the contact point on the tool, based on the center of the cutting tooth 15 tooth number of the tool, z. B. z75 helix angle in the pitch circle
Helix angle of the workpiece flank at different tooth heights
Tilt setting angle of the laser beam to the axis of rotation of the workpiece spindle in the X direction. Angular position of the laser beam to the axis of rotation of the workpiece spindle in the Y direction
tolerance
Tool setting angle in the axis position for machining
Tool part angle in the axis position for measuring
pitch angle
Angular positions of the CNC tool spindle
claims
1. A method for measuring a tool (1) for the rolling machining of toothed workpieces (3), the tool being rotatable about a tool axis (B) and having a plurality of cutting teeth (14), each of the cutting teeth forming a real cutting edge, and the method being carried out using a measuring device (11; 23), characterized in that the method comprises:
(a) calculating a virtual contact point (m1 to m5) on a virtual cutting edge (S) of a virtual tool (1 v), the virtual cutting edge extending along a longitudinal direction of the cutting edge and rounded off transversely to the longitudinal direction of the cutting edge;
(b) Calculating a relative orientation (Σ1 to Σ5) between the tool axis (B) and the measuring device (11; 23) and a translational relative position between the tool (1) and the measuring device (11; 23) on the basis

权利要求:
Claims (27)
[1]
the calculated virtual touch point (m1 to m5);
(c) setting the calculated relative orientation between the tool axis (B) and the measuring device (11; 23) and the calculated relative position between the tool (1) and the measuring device (11; 23); and (d) performing a measurement on the real cutting edge in the set relative orientation and relative position.
[2]
2. The method according to claim 1, wherein the above steps (a) to (d) for a plurality of virtual touch points (m1 to m5) are carried out along the virtual cutting edge (S).
CH 714 443 A1
[3]
3. The method according to claim 2, wherein a compensation curve (17) for the description of the real cutting edge is calculated from measurement results which have been determined for different contact points on the same real cutting edge.
[4]
4. The method according to claim 2 or 3, wherein at least one of the following parameters is determined from measurement results which have been determined for different contact points on the same real cutting edge:
at least one measure for the deviation of a profile of a flank made with the real cutting edge to a virtual flank made with the virtual cutting edge;
at least one measure of a change in the real cutting edge during rolling machining.
[5]
5. The method according to any one of the preceding claims, wherein the measurements in step (d) are carried out for a plurality of cutting teeth (14), and wherein at least one of the following parameters is determined from the measurements:
- tool runout;
- cutting tooth center;
- Tooth gap center.
[6]
6. The method according to any one of the preceding claims, wherein the measuring device (11) is spatially fixed during the implementation of the method and the setting of the relative orientation (Σ1 to Σ5) and the relative position is carried out by the orientation of the tool axis (B) in space and the position of the tool (1) can be changed in space.
[7]
7. The method according to any one of the preceding claims, wherein the measuring device (11; 23) provides a non-contact or touch probe, and wherein the relative orientation (Σ1 to Σ5) and the relative position are calculated and set such that the probe means the virtual cutting edge ( S) touches tangentially at the calculated virtual contact point (m1 to m5).
[8]
8. The method of claim 7, wherein the sensing means is cylindrical in shape.
[9]
9. The method of claim 8, wherein the sensing means defines a cylinder axis, a cylinder radius and a cylindrical sensing surface extending at a distance from the cylinder radius from the cylinder axis, and wherein the relative orientation (Σ1 to Σ5) and the relative position are calculated and set such that the cylinder axis runs parallel to a tangential plane on the virtual cutting edge (S) in the virtual contact point, and that the cylinder axis is at a distance from this tangential plane which corresponds to the cylinder radius.
[10]
10. The method according to claim 9, wherein the cylinder axis runs along an edge of a virtual workpiece (3v) which is in rolling engagement with the virtual tool (1v).
[11]
11. The method according to any one of claims 7 to 10,
- wherein the sensing means is formed by a light beam (12),
-wherein the tool (1) for performing the measurement in step (d) is rotated about the tool axis (B), and
- Detecting during the rotation at which actual angle of rotation the light beam is interrupted by the cutting edge.
[12]
12. The method of claim 11, wherein a deviation between the detected actual rotation angle and a target rotation angle calculated for the virtual cutting edge is determined.
[13]
13. The method according to claim 11 or 12, wherein the measurement in step (d) is carried out for several or all cutting teeth (14) of the tool (1) by rotating the tool (1) sufficiently about the tool axis (B), that several or all cutting teeth (14) successively interrupt and release the light beam (12).
[14]
14. The method according to any one of claims 7 to 10, wherein the sensing means is a cylindrical finger.
[15]
15. The method according to any one of the preceding claims, wherein the measurement in step (d) takes place at a measuring position (Mp), and wherein a calibration measurement for the measuring position (Mp) is carried out before and / or during the processing of a workpiece lot.
[16]
16. The method according to any one of the preceding claims, which further comprises at least the following steps:
(e) determining at least one setting for a machine control (8) on the basis of a result of the measurements; and (f) transferring the setting to the machine control (8), the setting causing a relative position between the workpiece (3) and the tool (1) to be set for machining a workpiece (3).
[17]
17. The method according to any one of the preceding claims, wherein the tool (1) is one of the following tools:
- a skiving tool; or
- a gear shaping tool.
[18]
18. The method according to any one of the preceding claims, wherein the method is carried out while the tool is on a tool spindle (2), with which machining of workpieces (3) also takes place.
CH 714 443 A1
[19]
19. Device for carrying out a method for measuring a tool (1) for the rolling machining of toothed workpieces (3), the tool (1) having a plurality of cutting teeth (14), each of the cutting teeth forming a real cutting edge, the device having:
- A tool spindle (2) for driving the tool (1) to rotate about a tool axis (B);
- a measuring device (11);
- At least one driven pivot axis (A) in order to change a relative orientation (Σ) between the tool axis (B) and the measuring device (11); and
at least one driven linear axis (X, Y, Z) in order to change a translational relative position between the tool (1) and the measuring device (11), characterized in that the device has a controller (8) which is designed to perform the following procedure:
(a) calculating a virtual contact point (m1 to m5) on a virtual cutting edge (S) of a virtual tool (Iv), the virtual cutting edge (S) extending along a cutting length direction and having a rounding transversely to the cutting length direction;
(b) Calculating a relative orientation (Σ 1 to Σ 5) between the tool axis (B) and the measuring device (11) and a translational relative position between the tool (1) and the measuring device (11) on the basis of the calculated virtual contact point (m1 up to m5);
(c) setting the calculated relative orientation (Σ1 to Σ5) and relative position by means of the swivel axis (A) and the at least one linear axis (X, Y, Z);
(d) Carrying out a measurement on the real cutting edge in the set relative orientation (Σ1 to Σ5) and relative position.
[20]
20. The apparatus of claim 19, wherein the controller performs the above steps (a) to (d) for a plurality of virtual touch points (m1 to m5) at different positions along the virtual cutting edge (S).
[21]
21. The apparatus of claim 19 or 20, wherein the measuring device (11) is arranged stationary during the measurement, wherein the pivot axis (A) is designed to change the orientation of the tool axis (B) in space relative to the fixed measuring device (11) , and wherein the at least one linear axis (X, Y, Z) is designed to change the translational position of the tool (1) in space relative to the measuring device (11).
[22]
22. The apparatus of claim 19 or 20, wherein the device comprises a machine bed (6) and a relative to the machine bed (6) movable, in particular pivotable, support (31) which is movable relative to the machine bed (6) between several positions, wherein the measuring device (11) is arranged on the movable carrier (31), and the measuring device (11) can be moved from a parking position into a measuring position by means of the movable carrier (31).
[23]
23. The apparatus of claim 22, wherein at least one workpiece spindle (4) for clamping a workpiece (3) to be machined is also arranged on the movable carrier (33).
[24]
24. Device according to one of claims 19 to 23, wherein the measuring device (11; 23) provides a non-contact or touch probe, and wherein the controller calculates and sets the relative orientation (Σ1 to Σ5) and the relative coordinates such that the probe means virtual cutting edge (S) tangentially touched in the calculated virtual contact point (m1 to m5).
[25]
25. The apparatus of claim 24, wherein the sensing means is cylindrical in shape.
[26]
26. The apparatus of claim 24 or 25, wherein the measuring device (11) has a light source and a light detector, wherein the light source is configured to generate a light beam (12) which is aligned with the light detector, and wherein the sensing means by at least an area of the light beam (12) is formed, the control interacting with the tool spindle (2) in such a way that the tool spindle (2) carries out the tool (1) for carrying out the measurement in the set relative orientation (Σ1 to Σ5) of the tool axis (B ) and at the set relative coordinates about the tool axis (B), and wherein the light detector is designed to detect during the rotation at which actual angle of rotation the light beam (12) is interrupted by the cutting edge.
[27]
27. The apparatus of claim 24 or 25, wherein the sensing means is a cylindrical finger.
CH 714 443 A1
CH 714 443 A1
17 ί2'Τ3'Τ4 ^χ Τ5

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同族专利:

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公开号 | 公开日

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WO2019115332A1|2019-06-20|

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US20200368835A1|2020-11-26|

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JP2021506598A|2021-02-22|

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CH714443A8|2019-09-13|

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CN111492199A|2020-08-04|

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EP3724598A1|2020-10-21|

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EP3724598B1|2022-01-19|

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KR20200096832A|2020-08-13|

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CH714443B1|2020-10-15|

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法律状态:
2019-07-31| PK| Correction|Free format text: BERICHTIGUNG ERFINDER |

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2019-09-13| PK| Correction|Free format text: BERICHTIGUNG ERFINDER |

优先权:

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申请号 | 申请日 | 专利标题

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CH01526/17A|CH714443B1|2017-12-15|2017-12-15|Method and device for measuring a rolling machining tool.|CH01526/17A| CH714443B1|2017-12-15|2017-12-15|Method and device for measuring a rolling machining tool.|

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KR1020207020571A| KR20200096832A|2017-12-15|2018-12-06|Method and apparatus for measuring generating machine tools|

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JP2020531739A| JP2021506598A|2017-12-15|2018-12-06|Methods and equipment for measuring creative machining tools|

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EP18815646.7A| EP3724598B1|2017-12-15|2018-12-06|Method and device for measuring a roll machining tool|

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US16/766,329| US20200368835A1|2017-12-15|2018-12-06|Method and device for measuring a roll machining tool|

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CN201880080956.3A| CN111492199A|2017-12-15|2018-12-06|Method and device for measuring a rolling tool|

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PCT/EP2018/083747| WO2019115332A1|2017-12-15|2018-12-06|Method and device for measuring a roll machining tool|