CN108941785B - Universal disc cutter composite milling process for large-modulus cylindrical outer gear - Google Patents

Universal disc cutter composite milling process for large-modulus cylindrical outer gear Download PDF

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CN108941785B
CN108941785B CN201810874540.0A CN201810874540A CN108941785B CN 108941785 B CN108941785 B CN 108941785B CN 201810874540 A CN201810874540 A CN 201810874540A CN 108941785 B CN108941785 B CN 108941785B
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tooth
milling
cutter
axis
enveloping
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CN108941785A (en
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于春建
方成刚
黄筱调
洪荣晶
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NANJING GONGDA CNC TECHNOLOGY CO LTD
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23FMAKING GEARS OR TOOTHED RACKS
    • B23F1/00Making gear teeth by tools of which the profile matches the profile of the required surface
    • B23F1/06Making gear teeth by tools of which the profile matches the profile of the required surface by milling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23FMAKING GEARS OR TOOTHED RACKS
    • B23F21/00Tools specially adapted for use in machines for manufacturing gear teeth
    • B23F21/12Milling tools
    • B23F21/14Profile cutters of disc type

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Abstract

A universal disc cutter composite milling device and a process thereof for a large-modulus cylindrical external gear can meet the requirements of rough machining and finish machining of the large-modulus cylindrical external gear with the diameter of more than 12mm based on the forming and enveloping gear milling machining principles. The universal disc cutter of the invention comprises: a disc-shaped cutter body (1), a hard alloy blade (2) and a fastening screw (3); the corresponding forming/enveloping compound gear milling machine mainly comprises: the numerical control milling machine comprises a machine body (4), a column (5), a Z-axis carriage (6), a Y-axis carriage (7), an A-axis plate angle carriage (8), a composite milling tooth spindle box (9), a numerical control rotary table (10), a bracket tool (11) and an external tooth cylindrical gear (12). The invention has the advantages that: the workpiece is clamped once, no tool is required to be changed in the processes of rough milling and semi-finish/finish milling, and the requirements of various tooth profiles/tooth direction modification and soft/hard tooth surface processing can be met.

Description

Universal disc cutter composite milling process for large-modulus cylindrical outer gear
Technical Field
The invention relates to the technical field of numerical control machining, in particular to a universal disc cutter composite milling device and a universal disc cutter composite milling process for a large-modulus cylindrical external gear, and belongs to the technical field of subjects and advanced manufacturing of numerical control technology and digital manufacturing and cutting machining process and equipment.
Technical Field
The large module gear generally refers to a gear with a module of more than 12mm, and the common machining process of the existing large module cylindrical external gear mainly comprises the following steps: the method comprises the following steps of forming and milling teeth, enveloping and milling teeth, generating and hobbing teeth, generating and gear shaping, forming and grinding teeth and disc cutter enveloping and milling teeth. For different tooth surface hardness and machining precision requirements, as shown in table 1, there are seven common machining processes as follows.
TABLE 1 existing teeth machining process for large modulus cylindrical external gear
Figure BDA0001752930330000011
The cutter-disc-shaped gear milling technology is an efficient, low-cost, green and environment-friendly gear processing technology and is widely applied. However, for finish milling, the defects of poor cutter universality and poor cutter and processing flexibility exist, and the market demand of medium and small-batch external tooth cylindrical gear processing cannot be met. The bar cutter enveloping gear milling process can partially make up the defects, has obvious advantages particularly in the aspect of processing herringbone gears with small tool withdrawal grooves, but has complex processing process, high cutter cost and low processing efficiency.
Disclosure of Invention
The invention provides a universal disc cutter composite milling device and a process thereof for a large-modulus cylindrical external gear, aiming at overcoming the defects of the processing process, the cutter of the universal disc cutter has a simple structure and low cost, can meet the high-efficiency rough and finish machining process of the large-modulus cylindrical external gear with the diameter of more than 12mm, can meet the requirements of various tooth shapes/tooth directions for shaping and soft/hard tooth surface processing, has strong processing flexibility, only needs one-time clamping of a workpiece without replacing the cutter, has higher processing efficiency, is green and environment-friendly, can achieve the GB7-8 level of processing precision, and has the processing efficiency 2-3 times that of the traditional hobbing and slotting gear.
The technical scheme of the invention is as follows:
the utility model provides a general disc cutter compound milling device of big modulus cylinder external gear which characterized in that adopts general disc cutter to mill the tooth, general disc cutter mainly include: the disc-shaped cutter body (1), the hard alloy blade (2) and the fastening screw (3) can simultaneously meet the requirements of high rigidity of the strongly formed milling teeth and high precision of the enveloped milling teeth.
The universal disc cutter is distributed in an insert type staggered tooth mode, side edges and top edges of axial sections of a rotary enveloping body of the disc cutter are straight in outline, and the side edges and the top edges are in arc transition at a tooth form angle of 15-20 degrees; the tooth side of the cylindrical outer gear is enveloped by a side edge of the cutter head in a micro-line section, the tooth root transition circular arc is enveloped by a circular arc at the top of the cutter head (the curvature radius of the circular arc at the top of the cutter head is smaller than the radius of the gear tooth root transition circular arc), and the tooth root circle is enveloped by a top edge of the cutter head.
The gear milling machine also comprises a forming/enveloping compound gear milling machine tool, and the forming/enveloping compound gear milling machine tool comprises: the numerical control lathe comprises a lathe body (4), a stand column (5) arranged on the lathe body (4), a numerical control rotary table (10), a Z-axis carriage (6), a Y-axis carriage (7), an A-axis pulling angle carriage (8), a composite milling tooth spindle box (9), a bracket tool (11) and an external gear cylindrical gear (12) which are arranged on the numerical control rotary table (10), wherein the disc-shaped cutter body (1) is arranged on the composite milling tooth spindle box (9), the lathe comprises three linear servo feeding shafts of an X axis, a Y axis and a Z axis, two rotary servo feeding shafts of an A axis and a C axis, and an SP axis is a universal disc cutter rotary shaft.
A general disc cutter composite milling process for a large-modulus cylindrical external gear is characterized by comprising a general disc cutter forming method rough machining process;
the rough machining process by the universal disc cutter forming method comprises the following steps: and the Y axis returns to the zero position, the symmetry center of the cutter head passes through the rotation center of the C axis, the A axis is pulled to a certain angle, the Z/C axis is subjected to linkage forward and backward milling after the X axis is subjected to radial feed, and the turntable is subjected to single indexing after each tooth socket is machined until all the tooth sockets are machined. In order to ensure the machining rigidity of the formed milling teeth, hydraulic locking is required to be carried out on the X axis and the Y axis.
The method also comprises a semi-fine/fine machining process of a universal disc cutter enveloping method;
the semi-fine/finish machining process of the universal disc cutter enveloping method comprises the following steps: firstly, an axis A is pulled to a certain angle, and an axis X/Y/C moves to a specified position; secondly, cutting the whole spiral tooth surface into a strip belt-shaped area along the tooth profile direction (the weft direction), performing Z/C axis linkage (the warp direction) along the warp, performing alternating reciprocating feeding along the reversed milling direction of (I) → the forward milling direction of (II) → the reversed milling direction of (III) … …', readjusting the position of the X/Y/C axis after finishing machining each tool, and enveloping the next tool until the tooth profile of the whole tooth socket is enveloped along the tooth profile direction; then, the rotary table is indexed to the next tooth groove, and the enveloping movement is repeated until the whole gear enveloping processing is finished.
The method also comprises a forming and milling tooth single-scale machining process; the forming gear milling single-division machining process comprises the following steps of dividing into one or more cutters (the cutter feeding is schematically shown as radial cutter feeding (IV) → radial cutter feeding (V) → tooth profile right tooth surface tangential cutter feeding (VI) → tooth profile left tooth surface tangential cutter feeding (VII)), wherein the single-side allowance is generally 2-3 mm, and more than 80% of machining allowance can be removed; the finish machining adopts an envelope method, the precision of the enveloped tooth profile depends on the setting size of residual height difference of the tooth surface, and is closely related to the enveloped cutter number, and the enveloped cutter number is 10-60 generally.
The method also comprises the step of adjusting the inclination angle beta' of the universal disc cutter during the forming and enveloping of the composite milling teeth: the contact line of the cutter head and the workpiece is positioned in a normal plane; then, roughly machining the formed milling teeth to remove more than 80% of machining allowance; finally, enveloping and milling the transition arcs of the tooth sides, the tooth roots and the tooth roots respectively by adopting the cutter profile in the normal plane, and calculating the minimum number of micro-line sections/arc enveloping cutters and corresponding enveloping paths according to the requirement of residual height difference along the weft direction in the gear normal plane; all the tooth milling processes are in a forward and reverse milling alternating mode along the warp direction, and idle stroke is reduced to the maximum extent.
The inclination angle beta' of the universal cutter head and the base circle helix angle beta of the workpiecebAnd cutter head tooth form angle alpha are related:
Figure BDA0001752930330000031
the cutter head tooth form angle alpha is 15-20 degrees, the corresponding forming milling tooth Y axis is located at a zero position, and the envelope milling tooth Y axis stroke is +/-220 mm;
and adjusting the rotating speed of the main shaft according to different cutting positions of the universal disc cutter corresponding to the enveloping process, so as to ensure constant linear speed of the enveloping gear milling. The diameter of the universal cutter head is 400-480 mm, the rotating speed of a main shaft is 100-180 rpm, the feeding speed of a formed milling tooth is 300-500 mm/min, and the feeding speed of an enveloped milling tooth is 800-1200 mm/min.
The invention has the beneficial effects that:
compared with the existing processing technology and machine tool, the invention has the main outstanding advantages that:
(1) all points of the hard alloy coating blade participate in cutting in the enveloping process, so that the blade is uniformly abraded, the service life of the blade is prolonged, and the cost of the cutter is reduced;
(2) the universal disc cutter can cover the processing ranges of different moduli and different tooth numbers, the processing flexibility is improved, and the cost and the period of the cutter are reduced;
(3) the universal disc cutter can simultaneously finish rough machining of formed milling teeth and semi-finish/finish machining of enveloped milling teeth, so that the machining auxiliary time is reduced, and secondary clamping errors of a cutter and a workpiece brought by procedure conversion are avoided;
(4) after the universal disc cutter is optimized by a pressure angle, the Y-direction stroke of a milling tooth spindle box in the enveloping process is shortened, and the eccentric quantity of the spindle box and the additional torque of a cutting load are reduced;
(5) the universal disc cutter composite milling process method can meet the requirements of various tooth shapes/tooth direction modification and soft/hard tooth surface processing, solves the problem of universality of the disc milling cutter, reduces the cost of the cutter and has strong flexibility;
(6) aiming at specific residual height difference requirements, the number of enveloping knives can be reduced as much as possible on the premise of ensuring enveloping precision, the enveloping machining precision is GB7-8 grade, the machining efficiency is 2-3 times that of the traditional hobbing and slotting gear, and the surface roughness is as follows: ra3.2;
(7) the universal disc cutter composite milling process method for the large-modulus cylindrical external gear mainly has the following outstanding advantages: the workpiece is clamped at one time, no tool is required to be changed in the processes of rough milling and semi-finish/finish milling, the requirements of various tooth profiles/tooth directions on shape modification and soft/hard tooth surface processing can be met, the problem of universality of the disc-shaped milling cutter is solved, the cost of the cutter is reduced, and the processing flexibility of the gear is improved.
Drawings
FIG. 1 is a schematic diagram of a universal disc cutter meridian enveloping method.
Fig. 1A is a partially enlarged schematic view of a in fig. 1.
Fig. 1B is a partially enlarged schematic view of B in fig. 1.
Fig. 2 is a schematic plan projection view of the universal disc cutter of the present invention.
FIG. 3a is a schematic diagram of a general disc cutter forming rough machining process.
Fig. 3b is a schematic diagram of a semi-finishing/finish-machining forming/enveloping composite gear milling process by a universal disc cutter enveloping method.
Fig. 4 is a schematic view of the general disc cutter of the invention.
Fig. 5 is an axial profile view of the universal cutter head rotary envelope of the present invention.
Fig. 6 is a schematic structural diagram of the universal disc cutter forming envelope composite gear milling machine tool.
Description of the components in the drawings: the numerical control milling cutter comprises a disk cutter body 1, a hard alloy blade 2, a fastening screw 3, a lathe bed 4, a stand column 5, a Z-axis carriage 6, a Y-axis carriage 7, an A-axis plate angle carriage 8, a composite milling tooth spindle box 9, a numerical control rotary table 10, a bracket tool 11 and an external tooth cylindrical gear 12.
Detailed Description
The technical content of the invention is described below with reference to the accompanying drawings:
as shown in fig. 1 to 6, a universal disc cutter compound milling device for a large-modulus cylindrical external gear and a process thereof are characterized in that the device can meet the requirements of rough and finish milling of the large-modulus cylindrical external gear with the diameter of more than 12mm based on the forming and enveloping machining principles of a cylindrical gear. A general disc cutter composite milling process method for a large-modulus cylindrical external gear is based on a cylindrical gear forming/enveloping machining principle, adopts a forming/enveloping composite gear milling machine tool, can meet the requirement of coarse/semi-fine/fine milling machining of the large-modulus and soft/hard tooth surface cylindrical external gear with the diameter of more than 12mm, clamps a workpiece at one time, does not need to replace a cutter, has two purposes and is strong in flexibility.
The first embodiment.
A universal disc cutter composite milling device for a large-modulus cylindrical external gear comprises a universal disc cutter, wherein the universal disc cutter mainly comprises: the disc-shaped cutter body (1), the hard alloy blade (2) and the fastening screw (3) can simultaneously meet the requirements of high rigidity of the strongly formed milling teeth and high precision of the enveloped milling teeth. The geometric parameters of the cutter head are the external contour parameters of the rotary envelope of the cutter head, and mainly comprise an outer diameter phi D, an effective milling width H, an effective milling depth L, a tooth form angle alpha and a circular arc radius R of a side edge and a top edge.
The universal disc cutter adopts insert type staggered tooth distribution, the side edge and the top edge of the axial section of a rotary enveloping body of the disc cutter are straight profiles, and the side edge and the top edge of a tooth-shaped angle of 15-20 degrees are in arc transition; the tooth side of the cylindrical outer gear is enveloped by a side edge of the cutter head in a micro-line section, the tooth root transition circular arc is enveloped by a circular arc at the top of the cutter head (the curvature radius of the circular arc at the top of the cutter head is smaller than the radius of the gear tooth root transition circular arc), and the tooth root circle is enveloped by a top edge of the cutter head.
Example two.
A universal disc cutter compound milling device for a large-modulus cylindrical external gear comprises a forming/enveloping compound gear milling machine tool, wherein the forming/enveloping compound gear milling machine tool comprises: the numerical control milling machine comprises a machine body (4), a column (5), a Z-axis carriage (6), a Y-axis carriage (7), an A-axis plate angle carriage (8), a composite milling tooth spindle box (9), a numerical control rotary table (10), a bracket tool (11) and an external tooth cylindrical gear (12). The disc-shaped cutter body (1) is arranged on a composite milling gear spindle box (9). The machine tool comprises three linear servo feed shafts of an X shaft, a Y shaft and a Z shaft, two rotary servo feed shafts of an A shaft and a C shaft, and an SP shaft is a rotary shaft of the universal disc cutter. The machine tool can simultaneously meet the requirements of high rigidity of the powerful forming milling teeth and high precision of the enveloping milling teeth.
Example three.
A general disc cutter composite milling process for a large-modulus cylindrical external gear is characterized by comprising a general disc cutter forming method rough machining process; the method also comprises a semi-fine/fine machining process of a universal disc cutter enveloping method; the method also comprises a forming and milling tooth single-scale machining process;
the universal disc cutter composite milling process method is also suitable for semi-finish milling processing and is used as a transition process before heat treatment (such as quenching) or finish machining (gear grinding); by setting reasonable finish machining allowance (determined according to heat treatment and finish machining requirements) and tooth profile residual height difference (about 0.1 mm), the finish machining allowance is ensured to be uniform, and the finish machining efficiency is improved.
The rough machining process by the universal disc cutter forming method comprises the following steps: and the Y axis returns to the zero position, the symmetry center of the cutter head passes through the rotation center of the C axis, the A axis is pulled to a certain angle, the Z/C axis is subjected to linkage forward and backward milling after the X axis is subjected to radial feed, and the turntable is subjected to single indexing after each tooth socket is machined until all the tooth sockets are machined. In order to ensure the machining rigidity of the formed milling teeth, hydraulic locking is required to be carried out on the X axis and the Y axis.
The semi-fine/finish machining process of the universal disc cutter enveloping method comprises the following steps: firstly, an axis A is pulled to a certain angle, and an axis X/Y/C moves to a specified position; secondly, cutting the whole spiral tooth surface into a strip belt-shaped area along the tooth profile direction (the weft direction), performing Z/C axis linkage (the warp direction) along the warp, performing alternating reciprocating feeding along the reversed milling direction of (I) → the forward milling direction of (II) → the reversed milling direction of (III) … …', readjusting the position of the X/Y/C axis after finishing machining each tool, and enveloping the next tool until the tooth profile of the whole tooth socket is enveloped along the tooth profile direction; then, the rotary table is indexed to the next tooth groove, and the enveloping movement is repeated until the whole gear enveloping processing is finished.
The forming gear milling single-division machining process comprises the following steps of dividing into one or more cutters (the cutter feeding is schematically shown as radial cutter feeding (IV) → radial cutter feeding (V) → tooth profile right tooth surface tangential cutter feeding (VI) → tooth profile left tooth surface tangential cutter feeding (VII)), wherein the single-side allowance is generally 2-3 mm, and more than 80% of machining allowance can be removed; the finish machining adopts an envelope method, the precision of the enveloped tooth profile depends on the setting size of residual height difference of the tooth surface, and is closely related to the enveloped cutter number, and the enveloped cutter number is 10-60 generally.
Preferably, when the composite gear milling is formed and enveloped, the inclination angle beta' of the universal cutter head is adjusted firstly, so that the contact line of the cutter head and the workpiece is in a normal plane; then, roughly machining the formed milling teeth to remove more than 80% of machining allowance; finally, enveloping and milling the transition arcs of the tooth sides, the tooth roots and the tooth roots respectively by adopting the cutter profile in the normal plane, and calculating the minimum number of micro-line sections/arc enveloping cutters and corresponding enveloping paths according to the requirement of residual height difference along the weft direction in the gear normal plane; all the tooth milling processes are in a forward and reverse milling alternating mode along the warp direction, and idle stroke is reduced to the maximum extent.
The inclination angle beta' of the universal cutter head and the base circle helix angle beta of the workpiecebAnd the cutter head tooth form angle alpha. The normal vector coincidence of any point of the contact line of the cutter head and the gear helicoid is obtained
Figure BDA0001752930330000071
And the tooth form angle alpha of the cutter head is 15-20 degrees, the corresponding forming milling tooth Y axis is positioned at a zero position, and the stroke of the envelope milling tooth Y axis is +/-220 mm.
On the section of the inclined angle beta' pulled by the A shaft, the tooth profile is in a non-involute tooth profile, the tangent solving is carried out on the section of the non-involute tooth profile through the straight profile edge of the milling cutter head, the tangent solving method in the section of the end is the same when the straight tooth is enveloped, and the enveloped cutter path is calculated through the control of the residual height difference of the equivalent method. Furthermore, β is the entire envelope of the tooth flankbAnd α is determined in advance, so β' is constant, i.e., the a-axis does not need to be angularly shifted during the envelope. The normal vectors of the contact lines of the cutter head and the workpiece are all positionedIn the normal plane.
According to different cutting positions of the universal disc cutter corresponding to the enveloping process, the rotating speed of the spindle can be automatically adjusted, and the constant linear speed of the enveloping gear milling is ensured. The diameter of the universal cutter head is 400-480 mm, the rotating speed of a main shaft is 100-180 rpm, the feeding speed of a formed milling tooth is 300-500 mm/min, and the feeding speed of an enveloped milling tooth is 800-1200 mm/min.
The rotating speed of the main shaft can be automatically adjusted at different positions of the cutter disc corresponding to the enveloping process, so that the constant linear speed of the enveloping gear milling is ensured. The composite milling process parameters are as follows:
Figure BDA0001752930330000072
the above-mentioned embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the concept and scope of the present invention, and various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the design concept of the present invention shall fall within the protection scope of the present invention, and the technical contents of the present invention which are claimed are all described in the claims.

Claims (1)

1. A general disc cutter composite milling process for a large-modulus cylindrical external gear is characterized by comprising a general disc cutter forming method rough machining process;
the rough machining process by the universal disc cutter forming method comprises the following steps: the Y axis returns to the zero position, the symmetry center of the cutter head passes through the rotation center of the C axis, the A axis is pulled to a certain angle, the Z/C axis is subjected to linkage forward and backward milling after the X axis is subjected to radial feed, and the turntable is subjected to single indexing after each tooth socket is machined until all the tooth sockets are machined; in order to ensure the machining rigidity of the formed milling teeth, the X axis and the Y axis both need to be hydraulically locked; the method also comprises a semi-fine/fine machining process of a universal disc cutter enveloping method;
the semi-fine/finish machining process of the universal disc cutter enveloping method comprises the following steps: firstly, an axis A is pulled to a certain angle, and an axis X/Y/C moves to a specified position; secondly, cutting the whole spiral tooth surface into a strip-shaped zone along the tooth profile direction, performing Z/C axis linkage along a meridian, performing reciprocating feed alternately along the 'reverse milling I → forward milling II → reverse milling III … …', readjusting the position of an X/Y/C axis after finishing machining of each cutter, and enveloping the next cutter until the tooth profile of the whole tooth slot is enveloped along the tooth profile direction; then, the rotary table is indexed to the next tooth groove, and the enveloping movement is repeated until the whole gear enveloping processing is finished;
the method also comprises a forming and milling tooth single-scale machining process; the forming and gear milling single-division machining process comprises the following steps of dividing the forming and gear milling single-division machining process into one-step or multi-step radial feed IV → radial feed V → tooth profile right tooth surface tangential feed VI → tooth profile left tooth surface tangential feed VII according to different gear modules, wherein the single-side allowance is generally 2-3 mm, and more than 80% of machining allowance can be removed; the finish machining adopts an envelope method, the precision of the enveloped tooth profile depends on the setting size of the residual height difference of the tooth surface, and is closely related to the enveloped cutter number, and the enveloped cutter number is 10-60 generally;
the method also comprises the step of adjusting the inclination angle beta' of the universal disc cutter during the forming and enveloping of the composite milling teeth: the contact line of the cutter head and the workpiece is positioned in a normal plane; then, roughly machining the formed milling teeth to remove more than 80% of machining allowance; finally, enveloping and milling the transition arcs of the tooth sides, the tooth roots and the tooth roots respectively by adopting the cutter profile in the normal plane, and calculating the minimum number of micro-line sections/arc enveloping cutters and corresponding enveloping paths according to the requirement of residual height difference along the weft direction in the gear normal plane; all the tooth milling processes are in a forward and reverse milling alternating mode along the warp direction, so that the idle stroke is reduced to the maximum extent;
the inclination angle beta' of the universal cutter head and the base circle helix angle beta of the workpiecebAnd cutter head tooth form angle alpha are related:
Figure FDA0002903714340000011
the cutter head tooth form angle alpha is 15-20 degrees, the corresponding forming milling tooth Y axis is located at a zero position, and the envelope milling tooth Y axis stroke is +/-220 mm;
adjusting the rotating speed of the main shaft according to different cutting positions of the universal disc cutter corresponding to the enveloping process to ensure constant linear speed of the enveloping gear milling; the diameter of the universal cutter head is 400-480 mm, the rotating speed of a main shaft is 100-180 rpm, the feeding speed of a formed milling tooth is 300-500 mm/min, and the feeding speed of an enveloped milling tooth is 800-1200 mm/min.
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