Double Roll NC Cutting Method of Spiral Bevel Gears with Small Module
-
摘要: 针对采用五刀法进行小模数螺旋锥齿轮加工时效率较低,采用两刀法加工时接触区不易于保证的问题,提出了采用双滚法进行小模数螺旋锥齿轮切齿的方法。设计了数控双滚加工流程,建立了刀位计算模型和自动对刀的相位补偿模型;开发了双滚加工数控软件,实现了在一个切齿加工循环中通过两次滚切完成齿轮副凹凸两面的加工,无需进行手动对刀处理。开展了切齿实验及滚动检查实验,验证了应用双滚加工方法进行小模数螺旋锥齿轮加工可在保证良好的接触状态的同时获得较高的加工效率。Abstract: Aiming at the low processing efficiency of spiral bevel gears with small modulus by means of five-step method and the difficulty of obtaining good contact area by Two-step method, a cutting method of spiral bevel gears with small modulus by using double rolling is presented. Designing NC double rolling process, the calculation model for tool position and the phase compensation model for automatic tool alignment are established, NC software for the double rolling is developed, the processing of concave and convex sides of gear pair through two rolling in a cutting cycle without manual tool alignment is realized. The experiments of cutting teeth and rolling inspection have been carried out. The results show that the double-rolling method can ensure the good contact and obtain the high processing efficiency for spiral bevel gears with small modulus.
-
Key words:
- spiral bevel gears /
- small module /
- double roll /
- tool alignment
-
表 1 实验齿轮副的基本参数
参数 大轮 小轮 齿数 41 4 模数 2.100 00 mm 齿面宽 14.00 mm 18.03 mm 小轮偏置距 17.00 mm 轴交角 90° 螺旋角 29°17′ 57°00′ 平均压力角 20°00′ 20°00′ 齿侧间隙 0.08 ~ 0.1 mm 旋向 右旋 左旋 表 2 小轮双滚加工刀具及机床调整参数
参数 凹面 凸面 刀尖直径 76.99 mm 75.40 mm 刀齿齿形角 17°20′ 22°40′ 刀尖圆角半径 0.18 mm 0.18 mm 机床安装根锥角 5°25′ 5°25′ 水平轮位 −0.46 mm 0.71 mm 床位 2.03 mm 1.92 mm 垂直轮位 16.00 mm 17.64 mm 径向刀位 36.664 6 mm 37.850 7 mm 滚比值 9.984 5 10.662 5 起始摇台角 65.815 3° 66.101 6° 基本摇台角 93.330 4° 84.919 8° 终止摇台角 113.999 5° 108.013° -
[1] 罗建勤, 汪慧君, 吕传贵. 我国小模数弧齿锥齿轮制造技术综述[J]. 机械传动, 2013, 37(12): 160-162Luo J Q, Wang H J, Lv C G. Summary of small module spiral bevel gear manufacturing technology in China[J]. Journal of Mechanical Transmission, 2013, 37(12): 160-162 (in Chinese) [2] Shtipelman B A. Design and manufacture of hypoid gears[M]. New York: Wiley, 1978 [3] Litvin F L, Chen N X, Chen J S, et al. Computerized design and generation of low-noise gears with localized bearing contact[Z]. Virginia: NASA, 1994: 1-12 [4] 魏冰阳, 邓效忠, 仝昂鑫, 等. 曲面综合法弧齿锥齿轮加工参数计算[J]. 机械工程学报, 2016, 52(1): 20-25 doi: 10.3901/JME.2016.01.020Wei B Y, Deng X Z, Tong A X, et al. Surface synthesis method on generating parameters computation of spiral bevel-gears[J]. Journal of Mechanical Engineering, 2016, 52(1): 20-25 (in Chinese) doi: 10.3901/JME.2016.01.020 [5] 方宗德, 杨宏斌, 邓效忠. 弧齿锥齿轮齿面优化修正及计算机仿真[J]. 航空动力学报, 2002, 17(1): 140-144 doi: 10.3969/j.issn.1000-8055.2002.01.026Fang Z D, Yang H B, Deng X Z. Optimal tooth surface correction of spiral bevel gears and computerized simulation[J]. Journal of Aerospace Power, 2002, 17(1): 140-144 (in Chinese) doi: 10.3969/j.issn.1000-8055.2002.01.026 [6] Gleason W. Calculation instructions generated hypoid gears duplex helical method[M]. New York: The Gleason Works, 1971 [7] 吕传贵, 罗建勤, 汪慧君. 螺旋双面法加工小模数准双曲面锥齿轮的切齿计算[J]. 机械传动, 2018, 42(7): 92-95, 111Lü C G, Luo J Q, Wang H J. Tooth cutting calculation of helical double-sided machining of small module quasi-hyperboloid bevel gear[J]. Journal of Mechanical Transmission, 2018, 42(7): 92-95, 111 (in Chinese) [8] 张华, 蒋亚波, 杨建军, 等. 小模数弧齿锥齿轮设计与加工的新方法[J]. 机床与液压, 2016, 44(23): 50-56 doi: 10.3969/j.issn.1001-3881.2016.23.012Zhang H, Jiang Y B, Yang J J, et al. Small module spiral bevel gears design and new machining method[J]. Machine Tool & Hydraulics, 2016, 44(23): 50-56 (in Chinese) doi: 10.3969/j.issn.1001-3881.2016.23.012 [9] 张华, 刘高杰, 徐林林, 等. 小模数弧齿锥齿轮的三维建模与应用分析[J]. 机械传动, 2013, 37(9): 42-45Zhang H, Liu G J, Xu L L, et al. 3D modeling and applied analysis of small-module spiral bevel gear[J]. Journal of Mechanical Transmission, 2013, 37(9): 42-45 (in Chinese) [10] 张宇, 严宏志, 曾韬. 弧齿锥齿轮双重螺旋法切齿原理及齿面接触分析研究[J]. 机械工程学报, 2015, 51(21): 15-23 doi: 10.3901/JME.2015.21.015Zhang Y, Yan H Z, Zeng T. Cutting principle and tooth contact analysis of spiral bevel and hypoid gears generated by duplex helical method[J]. Journal of Mechanical Engineering, 2015, 51(21): 15-23 (in Chinese) doi: 10.3901/JME.2015.21.015 [11] Zhang Y, Yang H Z. New methodology for determining basic machine settings of spiral bevel and hypoid gears manufactured by duplex helical method[J]. Mechanism and Machine Theory, 2016, 100: 283-295 doi: 10.1016/j.mechmachtheory.2016.02.015 [12] Gonzalez-Perez I, Fuentes A, Hayasaka K. Computerized design and tooth contact analysis of spiral bevel gears generated by the duplex helical method[C]//ASME 2011 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. Washington, DC, USA: ASME, 2011: 149-158 [13] Stadtfeld H J.锥齿轮齿形加工的第二次革命[J].孙季初, 译.世界制造技术与装备市场, 2004,(5): 71-75Stadtfeld H J, Sun J C. Second revolution for the bevel gear forming machining[J]. Sun J C, trans. World Manufacturing Engineering & Market, 2004, (5): 71-75 (in Chinese) [14] 张卫青, 张明德, 郭晓东, 等. 全数控锥齿轮铣齿机运动控制方法及切齿实验研究[J]. 中国机械工程, 2009, 20(22): 2733-2737 doi: 10.3321/j.issn:1004-132X.2009.22.018Zhang W Q, Zhang M D, Guo X D, et al. Research on the kinematic control method of CNC hypoid cutting machine and the cutting experiments[J]. China Mechanical Engineering, 2009, 20(22): 2733-2737 (in Chinese) doi: 10.3321/j.issn:1004-132X.2009.22.018 [15] 张明德, 张卫青, 郭晓东. 全数控锥齿轮铣齿机切齿软件开发[J]. 制造技术与机床, 2009,(11): 102-105 doi: 10.3969/j.issn.1005-2402.2009.11.033Zhang M D, Zhang W Q, Guo X D. The development of CNC hypoid cutting machine software[J]. Manufacturing Technology & Machine Tool, 2009,(11): 102-105 (in Chinese) doi: 10.3969/j.issn.1005-2402.2009.11.033