CN111283923B - Method for shaping and processing plastic cement tooth-direction drum-shaped gear - Google Patents
Method for shaping and processing plastic cement tooth-direction drum-shaped gear Download PDFInfo
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- CN111283923B CN111283923B CN202010089802.XA CN202010089802A CN111283923B CN 111283923 B CN111283923 B CN 111283923B CN 202010089802 A CN202010089802 A CN 202010089802A CN 111283923 B CN111283923 B CN 111283923B
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- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000012545 processing Methods 0.000 title claims abstract description 25
- 238000007493 shaping process Methods 0.000 title description 4
- 239000004568 cement Substances 0.000 title description 3
- 238000007599 discharging Methods 0.000 claims abstract description 14
- 238000009760 electrical discharge machining Methods 0.000 claims abstract description 9
- 238000001746 injection moulding Methods 0.000 claims abstract description 7
- 238000013461 design Methods 0.000 claims abstract description 6
- 238000010862 gear shaping Methods 0.000 claims abstract description 5
- 238000003672 processing method Methods 0.000 claims abstract description 5
- 238000003754 machining Methods 0.000 claims description 33
- 238000004519 manufacturing process Methods 0.000 claims description 12
- 238000009826 distribution Methods 0.000 abstract description 3
- 238000005461 lubrication Methods 0.000 abstract description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 abstract description 2
- 229910052802 copper Inorganic materials 0.000 abstract description 2
- 239000010949 copper Substances 0.000 abstract description 2
- 238000012986 modification Methods 0.000 description 5
- 230000004048 modification Effects 0.000 description 5
- 230000005540 biological transmission Effects 0.000 description 4
- 238000006073 displacement reaction Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
- B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
A plastic gear tooth direction crowned gear shaping processing method comprises the following steps: step 1, confirming the crown quantity of a tooth-direction crown gear according to a conventional design method of the tooth-direction crown gear; step 2, firstly, a drum-free thick male electrode is manufactured by a common hob, and a rough die core is manufactured by rough electrical discharge machining on a spark machine; step 3, processing a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, putting the drum-shaped fine male electrode into a rough die core, performing fine work discharging, and processing a fine die core according to drum shape; and 4, performing injection molding by using the fine mold core, and demolding in a forced demolding manner to obtain the plastic facing drum-shaped gear. The copper tool and the die core used in the die are comprehensively utilized to process the tooth direction drum shape, the lubrication state of the tooth surface is improved, more uniform load distribution is obtained, the bearing capacity is improved, and the vibration and the noise are reduced.
Description
Technical Field
The invention relates to a gear processing technology, in particular to a plastic gear tooth direction drum gear shaping processing method.
Background
With the development of a miniature gear transmission system, the plastic gear gradually replaces a hardware gear with the advantages of low cost, high molding efficiency and the like, and is widely applied. However, plastic gears are developed and processed late in China, and related design requirements of hardware gears are still used for design and processing, so that actual production requirements cannot be met. The plastic gear is subjected to shrinkage due to molding errors caused by pressure maintaining, injection pressure, temperature and the like in the molding process, so that manufacturing errors are caused, meshing impact is caused in the transmission process of the gear box body, and noise is caused due to unstable transmission.
Disclosure of Invention
In order to solve the technical problems, the invention provides a method for shaping and processing a plastic cement tooth-direction drum-shaped gear, which comprehensively utilizes a copper tool and a mold core used in a mold to process the tooth-direction drum shape, improves the lubrication state of a tooth surface, obtains more uniform load distribution, improves the bearing capacity and reduces vibration and noise.
In order to realize the technical purpose, the adopted technical scheme is as follows: a plastic gear tooth direction crowned gear shaping processing method comprises the following steps:
step 1, confirming the crown quantity of a tooth-direction crown gear according to a conventional design method of the tooth-direction crown gear;
step 2, firstly, a drum-free thick male electrode is manufactured by a common hob, and a rough die core is manufactured by rough electrical discharge machining on a spark machine;
step 3, processing a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, putting the drum-shaped fine male electrode into a rough die core, performing fine work discharging, and processing a fine die core according to drum shape;
and 4, performing injection molding by using the fine mold core, and demolding in a forced demolding manner to obtain the plastic facing drum-shaped gear.
The drum shape quantity delta is expressed as delta ≈ 2Fβ0.001 to 0.003mm, and F is a manufacturing error of 0.001 to 0.003mmβIs the tooth direction overall error.
The specific implementation method of the step 2 is as follows: firstly, a non-drum-shaped thick male electrode is manufactured by using a common hob, the tooth width of the non-drum-shaped thick male electrode is A, rough electrical discharge machining is carried out on a spark machine, a rough mold core is manufactured, the tooth thickness of the mold core is X = A + (C0X 2), and C0 is a rough single-side spark position.
The specific implementation method of the step 3 is as follows:
step 3.1, machining a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, wherein the minimum position tooth thickness of the fine male electrode is B1, the maximum position tooth thickness is B2, placing the fine male electrode into a rough machining die core for finish machining and discharging, machining the rough machining die core according to B1+ (C1) to obtain the minimum position tooth thickness A1, A1 is less than B1+ (C1) 2, machining the rough machining die core according to B2+ (C1) to obtain the maximum position tooth thickness A2, A2 is less than B2+ (C1) and C1 is a rough single-side spark position, and obtaining a secondary die core;
and 3.2, performing fine discharge on the secondary mold core by using a fine male electrode with the minimum position tooth thickness of B1 and the maximum position tooth thickness of B2, processing the secondary mold core according to A1+ (0.15X 2) to obtain the minimum position tooth thickness A3, A3= A1+ (C2X 2), C2 is a fine single-side spark position, processing the secondary mold core according to A3+ (. DELTA.. times.2) to obtain the maximum position tooth thickness A4, and A4= A3+ (. DELTA.. times.2), and thus obtaining the fine mold core.
The value ranges of C0 and C1 are 0.1-0.15 mm.
The value range of C2 is 0.05-0.075 mm.
The invention has the beneficial effects that: the method for processing the modification of the tooth-direction drum shape improves the original conventional electrode and mold core manufacturing mode, conventional discharging can not be satisfied, and a five-axis numerical control gear hobbing machine is adopted to process the displacement electrode because the conventional hob can not manufacture the displacement electrode, and the mold core is processed by using the discharging mode, so that the method is used for injection molding of the plastic gear with the drum shape modification, and the current situation that the existing plastic gear can not be molded with the drum shape modification is changed. More uniform load distribution is obtained, gear transmission noise is reduced, and the tooth surface lubrication state can be improved by performing tooth-direction drum shape modification on the plastic gear. The shrinkage phenomenon in the middle of the formed tooth width is compensated, the tooth direction drum shape modification can compensate the waist shrinkage, and the uniform thickness of the gear glue position is realized.
Drawings
FIG. 1 is a schematic view of an axial crown gear;
FIG. 2 is a schematic view of FIG. 1A;
FIG. 3 is a process diagram of example 1 of the present invention.
Detailed Description
A plastic gear tooth direction crowned gear shaping processing method comprises the following steps:
step 1, confirming the crown quantity of a tooth-direction crown gear according to a conventional design method of the tooth-direction crown gear;
step 2, firstly, a drum-free thick male electrode is manufactured by a common hob, and a rough die core is manufactured by rough electrical discharge machining on a spark machine; the specific method comprises the following steps: firstly, a non-drum-shaped thick male electrode is manufactured by using a common hob, the tooth width of the non-drum-shaped thick male electrode is A, rough electrical discharge machining is carried out on a spark machine, a rough mold core is manufactured, the tooth thickness of the mold core is X = A + (C0X 2), and C0 is a rough single-side spark position.
Step 3, processing a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, putting the drum-shaped fine male electrode into a rough die core, performing fine work discharging, and processing a fine die core according to drum shape;
step 3.1, machining a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, wherein the minimum position tooth thickness of the fine male electrode is B1, and the maximum position tooth thickness is B2, placing the fine male electrode into a rough machining die core for finish machining and discharging, machining the rough machining die core according to B1+ (C1) to obtain the minimum position tooth thickness A1, A1 is less than B1+ (C1) and machining the rough machining die core according to B2+ (C1) to obtain the maximum position tooth thickness A2, A2 is less than B2+ (C1) and C1 is a rough machining single-edge spark position to obtain a secondary die core with the minimum position tooth thickness A1 and the maximum position tooth thickness A2;
and 3.2, performing fine discharge on the secondary mold core by using a fine male electrode with the minimum position tooth thickness of B1 and the maximum position tooth thickness of B2, processing the secondary mold core according to A1+ (0.15 × 2) to obtain the minimum position tooth thickness A3, A3= A1+ (C2 × 2), and C2 to obtain a fine single-side spark position, processing the secondary mold core according to A3+ (. DELTA.. times.2) to obtain the maximum position tooth thickness A4, and A4= A3+ (. times.2), and obtaining the fine mold core with the minimum position tooth thickness of A3 and the maximum position tooth thickness of A4.
And 4, performing injection molding by using a fine mold core, and demolding in a forced demolding manner to obtain the plastic facing drum gear, as shown in figures 1 and 2.
After the drum-shaped mold core is machined, the drum-shaped mold core is assembled on a mold for injection molding production, and the plastic gear is integrally subjected to internal shrinkage after injection molding and cooling shaping so as to reduce the back-off amount generated by a drum-shaped part, so that a drum-shaped tooth form mold stripping mode adopts a forced stripping mode, the mold structure and the molding process can be simplified, and the mold stripping efficiency can be improved.
The drum shape quantity delta is expressed as delta ≈ 2Fβ0.001 to 0.003mm, and F is a manufacturing error of 0.001 to 0.003mmβIs the tooth direction overall error.
The invention is suitable for the occasions of 0.3-0.9 modulus plastic gears, thicker material thickness in the middle of the tooth width, thicker tooth thickness of straight gears or helical gears, higher requirement on noise and sensitive to the uniform degree of load bearing.
For plastic gears with a modulus of 0.3-0.9, according to actual processing experience and theoretical knowledge, a drum shape (back-off quantity) delta formula is as follows:
△≈2Fβ+(0.001～0.003)，0.001 to 0.003mm is a manufacturing error, FβAnd (3) taking a value according to 10-grade precision in the ISO 1328-2(1997) standard for the tooth direction overall error.
For a plastic gear with a modulus of 0.3-0.9, the drum shape quantity delta generally ranges from 0.01-0.06 mm, the minimum position tooth thickness of the fine die core is recorded as A3, the maximum position drum shape tooth thickness of the fine die core is recorded as A4, and the process method for processing the fine die core comprises the following steps:
1. recording the tooth width of the drum-free thick male electrode as A, and the tooth thickness of the die core as X, wherein X = A + (0.15X 2), and the rough single-side spark position is 0.15 mm;
2. the minimum position tooth thickness of a drum electrode machined by the numerical control gear hobbing machine is B1, and the maximum position drum tooth thickness is B2: recording the minimum position tooth thickness of the mold core after rough electrical discharge machining as A1 and the maximum position drum-shaped tooth thickness of the mold core as A2, then
A1＜B1+（0.15*2）
A2 < B2+ (0.15 x 2) rough single-side spark position 0.15 mm;
the electrode is seriously lost in the processing process and the surface is rough due to the fact that the current or the voltage is large in the discharging process, and the like, so that the fine discharging is needed.
3. Recording the tooth thickness of the minimum position of the mold core after the fine electrical discharge machining as A3, and the drum-shaped tooth thickness of the maximum position of the mold core as A4; from step 2, the minimum tooth thickness of the rough mold core is A1, and the maximum crowned tooth thickness is A2, then
A3=A1+（0.075*2）
A4= A3+ (Δ × 2) fine single-edge spark spot 0.075 mm;
note: the range of rough single-side spark positions is as follows: 0.1-0.15 mm, if the single-side spark position of the rough workpiece is greater than 0.15mm, the surface of the workpiece is rough and can not meet the use requirement; the processing range of the finish single-side spark position is as follows: 0.05-0.075 mm, if the unilateral spark position of finish worker >0.075mm, the work piece surface is crude, can not satisfy the operation requirement.
Example 1
The common gear blank processing can be directly finished by adopting a conventional hob to manufacture an electrode firstly and then carry out discharge processing directly, the gear direction drum-shaped gear blank is a displacement electrode, and the conventional hob can not manufacture the displacement electrode, so a five-axis numerical control gear hobbing machine is adopted to process the gear direction drum-shaped electrode, if the requirement that the gear thickness of the drum-shaped maximum position of a finish machining mold core is 1.85, the gear thickness of the drum-shaped minimum position of the finish machining mold core is 1.75, and the drum-shaped quantity delta is 0.05mm, the processing technique method comprises the following steps:
1. a 1.40 drum-free thick male electrode is processed by using a conventional hob, then the discharge machining is carried out on a cremation machine, the unilateral spark position C0=0.15, and a thick die insert with the tooth thickness of 1.4+ (0.5 × 2) =1.70 is processed, as shown in the left side of the figure 3;
2. a fine male electrode with a maximum position drum shape of 1.55 and a minimum position drum shape of 1.45 is machined by a five-axis numerical control gear hobbing machine, then a fine die core is machined, a rough machining discharging unilateral spark position C1=0.15, and due to the fact that the electrode is seriously lost and the surface is rough in the machining process caused by large current or voltage in the discharging process, the electrode is machined until the maximum position tooth thickness A2 of the coarse die core is 1.7 and the minimum position tooth thickness A1 of the coarse die core is 1.6, a fine machining unilateral spark position C2=0.075 for fine machining is adopted, finally, the drum shape tooth thickness at the minimum position is 1.6+ (0.075 x 2) =1.75, and the maximum position drum shape tooth thickness is 1.75+ (0.05 x 2) =1.85, as shown on the right side of fig. 3.
Claims (1)
1. A plastic tooth direction drum gear shaping processing method is characterized in that: the method is suitable for the plastic gear with the modulus of 0.3-0.9, and comprises the following steps:
step 1, confirming the crown quantity of a tooth-direction crown gear according to a conventional design method of the tooth-direction crown gear;
the drum shape quantity delta is expressed as delta ≈ 2Fβ0.001 to 0.003mm, and F is a manufacturing error of 0.001 to 0.003mmβThe value range of the drum-shaped quantity delta is 0.01-0.06 mm, which is the total error of the tooth direction;
step 2, firstly, a drum-free thick male electrode is manufactured by a common hob, and a rough die core is manufactured by rough electrical discharge machining on a spark machine;
the specific implementation method comprises the following steps: firstly, a common hob is used for manufacturing a drum-free thick male electrode, the tooth width of the drum-free thick male electrode is A, rough electrical discharge machining is carried out on a spark machine, a rough die core is manufactured, the tooth thickness X = A + (C0X 2) of the die core is C0 of a rough single-side spark position, and the value range of C0 is 0.1-0.15 mm;
step 3, processing a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, putting the drum-shaped fine male electrode into a rough die core, performing fine work discharging, and processing a fine die core according to drum shape;
the specific implementation method of the step 3 is as follows:
3.1, machining a drum-shaped fine male electrode by using a five-axis numerical control gear hobbing machine, wherein the minimum position tooth thickness of the fine male electrode is B1, the maximum position tooth thickness is B2, placing the fine male electrode into a rough machining die core for finish machining and discharging, machining the rough machining die core according to B1+ (C1) to obtain the minimum position tooth thickness A1, A1 is less than B1+ (C1) 2, machining the rough machining die core according to B2+ (C1) to obtain the maximum position tooth thickness A2, A2 is less than B2+ (C1) 2, C1 is a rough single-side spark position to obtain a secondary die core, and the value ranges of C0 and C1 are 0.1-0.15 mm;
step 3.2, carrying out precision machining discharging on the secondary mold core by using a precision male electrode with the minimum position tooth thickness of B1 and the maximum position tooth thickness of B2, machining the secondary mold core according to A1+ (0.15 × 2) to obtain the minimum position tooth thickness A3, A3= A1+ (C2 × 2), C2 is a precision single-side spark position, the value range of C2 is 0.05-0.075 mm, machining the secondary mold core according to A3+ (Δ2) to obtain the maximum position tooth thickness A4, A4= A3+ (Δ × 2), and obtaining the precision machining mold core;
and 4, performing injection molding by using the fine mold core, and demolding in a forced demolding manner to obtain the plastic facing drum-shaped gear.
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| CN202010089802.XA CN111283923B (en) | 2020-02-13 | 2020-02-13 | Method for shaping and processing plastic cement tooth-direction drum-shaped gear |
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| CN202010089802.XA CN111283923B (en) | 2020-02-13 | 2020-02-13 | Method for shaping and processing plastic cement tooth-direction drum-shaped gear |
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| CN111842522A (en) * | 2020-07-01 | 2020-10-30 | 重庆众联齿轮传动有限公司 | Female die for molding drum-shaped teeth |
| CN112590071A (en) * | 2020-12-11 | 2021-04-02 | 惠州威博精密科技有限公司 | Injection mold sliding block machining method, mold and product forming method |
| CN113790254B (en) * | 2021-08-20 | 2022-06-21 | 浙江汇丰汽车零部件股份有限公司 | Plastic gear and mold opening method thereof |
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