CN111515469A - Machining method for manufacturing orthogonal straight-tooth face gear by disc-shaped cutter - Google Patents

Machining method for manufacturing orthogonal straight-tooth face gear by disc-shaped cutter Download PDF

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CN111515469A
CN111515469A CN202010265204.3A CN202010265204A CN111515469A CN 111515469 A CN111515469 A CN 111515469A CN 202010265204 A CN202010265204 A CN 202010265204A CN 111515469 A CN111515469 A CN 111515469A
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disc
cutter
numerical control
shaped cutter
face gear
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CN111515469B (en
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彭先龙
赵朋辉
江晓瑜
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Xian University of Science and Technology
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Xian University of Science and Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F5/00—Making straight gear teeth involving moving a tool relatively to a workpiece with a rolling-off or an enveloping motion with respect to the gear teeth to be made
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F21/00—Tools specially adapted for use in machines for manufacturing gear teeth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23F—MAKING GEARS OR TOOTHED RACKS
    • B23F5/00—Making straight gear teeth involving moving a tool relatively to a workpiece with a rolling-off or an enveloping motion with respect to the gear teeth to be made
    • B23F5/02—Making straight gear teeth involving moving a tool relatively to a workpiece with a rolling-off or an enveloping motion with respect to the gear teeth to be made by grinding

Abstract

The invention relates to the field of gear manufacturing, and discloses a processing method for manufacturing an orthogonal straight-tooth face gear by using a disc-shaped cutter, which comprises the following steps: establishing a coordinate system, setting the initial position of a disc-shaped cutter, setting the motion rule of the disc-shaped cutter, designing the disc-shaped cutter, selecting a numerical control machine, compiling a numerical control program and cutting a face gear. The initial position and the motion rule of the disc-shaped cutter determine the motion process of the disc-shaped cutter relative to the orthogonal straight-tooth face gear, except for cutting motion, only the disc-shaped cutter rotates, but the orthogonal straight-tooth face gear only needs indexing motion, and the machining process can be realized by applying a five-axis numerical control machine tool with three-axis linkage. The shape generating lines of the disc-shaped cutter are all straight lines, and the cutter structure is simple and easy to manufacture and repair. For an orthogonal straight-tooth face gear with the modulus of 6.35mm and the tooth number of 160, the tooth surface deviation is only 82.6 mu m, which is less than one tenth of the tooth surface deviation of a Gralison plane cutter machined face gear, and the tooth surface precision is greatly improved. The method can be used for not only cutting teeth but also grinding teeth.

Description

Machining method for manufacturing orthogonal straight-tooth face gear by disc-shaped cutter
Technical Field
The invention relates to the field of gear manufacturing, in particular to a machining method for manufacturing an orthogonal straight-tooth face gear by using a disc-shaped cutter.
Background
The orthogonal straight tooth face gear is meshed with the involute cylindrical gear, the axes of the orthogonal straight tooth face gear and the involute cylindrical gear are intersected, and the included angle is a right angle. When the involute cylindrical gear is rotated, the involute curved surface of the involute cylindrical gear envelops the tooth-shaped curved surface of the orthogonal straight-tooth face gear. The existing processing methods of the orthogonal straight tooth face gear are all based on the simulation of the meshing process, and the processing methods are mainly divided into two categories: one of the methods is a linear contact processing method, such as processing an orthogonal straight-tooth face gear (f.l. litvin, Handbook on face gear drive with a space inertia impact, 2000, NASA/CR-2000) 209909) by using a slotting cutter the same as an involute cylindrical gear, the slotting processing efficiency is not high, the tooth surface quality is low, and because the orthogonal straight-tooth face gear is generally used in high-speed heavy-load occasions, the slotting cannot meet the processing quality requirement of the orthogonal straight-tooth face gear. Another line contact machining method is the gritson's plane tool machining method (US20120099939a1, CN103264198A), the contact line of the tool and the workpiece is basically along the tooth width direction, but large tooth surface deviation is introduced, and the dynamic quality of the meshing transmission of the orthogonal straight tooth surface gear is reduced. The second type of machining method is a point contact machining method, such as a worm tool (US006146253A) and an involute disc tool (CN103530458A, CN106238830A), which can achieve continuous indexing and high machining efficiency, but the tool is extremely complex and the involute disc tool is simple, but because of single-tooth indexing, tooth height and tooth direction bidirectional feeding are required, the efficiency is extremely low, and another outstanding problem for point contact machining is that the production line of the tool is an involute of an involute cylindrical gear, so that parameters of the involute cylindrical gear, such as tooth number, modulus and pressure angle, are slightly changed, and the tool must be redesigned, manufactured and trimmed, in other words, the tool has no universality.
Aiming at the problems of low efficiency, low tooth surface quality, low precision, complex cutter, incapability of being used universally and the like in the processing of an online contact processing method, a processing method for manufacturing an orthogonal straight tooth surface gear by a disc cutter is provided, wherein the shape generating lines of the cutter are all straight lines and are irrelevant to the involute of a cylindrical gear, so that the cutter is simple and simple in structure; the cutter is in line contact with the tooth surface of the processed orthogonal straight tooth surface gear, so that the processing efficiency is high; the machining of the workpiece can be realized on the existing three-linkage 5-axis numerical control machine tool, and the motion rule is extremely simple; in addition, the machined tooth surface deviation is extremely small. The problems of motion rule, cutter, numerical control program and the like in the processing method are explained.
Disclosure of Invention
In order to solve the technical problem, the invention provides a processing method for manufacturing an orthogonal straight-tooth face gear by using a disc-shaped cutter.
In order to achieve the purpose, the invention adopts the technical scheme that:
a processing method for manufacturing an orthogonal straight-tooth face gear by a disc-shaped cutter comprises the following steps: establishing a coordinate system, setting the initial position of a disc-shaped cutter, setting the motion rule of the disc-shaped cutter, designing the disc-shaped cutter, selecting a numerical control machine, compiling a numerical control program and cutting a face gear.
As a preferred mode, establishing the coordinate system includes: establishing a coordinate system S of orthogonal straight face gears2(x2y2z2O2) Wherein z is2Coincident with the axis of the orthogonal spur gear, S2Origin O of2The distance from the pitch cone surface of the orthogonal straight tooth face gear is rps，rpsIs the radius of the reference circle of the imaginary involute profile wheel; establishing an auxiliary coordinate system Sp(xpypzpOp) Wherein x isp∥z2，yp∥y2，zp∥x2，SpRelative to S2Along x2、y2、z2Translating; establishing a disc cutter coordinate system Sc(xcyczcOc) In which S iscOrigin O ofcAnd SpOrigin O ofpCoincidence, ycAnd ypCoincidence, ScOrigin O ofcIs the center of the disc cutter, z2Coinciding with the axis of the disc cutter, ScAt SpMiddle winding ypAnd (4) rotating.
As a preferred mode, the setting of the initial position of the disc cutter includes three distances and an included angle, and the three distances are respectively: spRelative to S2At x2、y2、z2Distance C ofx、Cy、CzRespectively expressed as:
Cx＝-0.25·π·m·cos2α+u0·sinα-rc·sinα0，
Cy＝m·N2/2，
Cz＝0.25·π·m·cosα·sinα+u0·cosα+rc·cosα0-rps，
where m is the modulus, α is the pressure angle, rc、u0α, the distances from the intersection point of the conical surface shape-generating line of the disc cutter and the plane shape-generating line of the cutter body to the axis of the disc cutter and the midpoint of the conical surface shape-generating line0＝αc-α，αcThe inclination angle of the conical surface shape-generating line of the disc-shaped cutter is equal to the acute angle N between the conical surface shape-generating line and the plane shape-generating line of the cutter body2The number of teeth of the straight-tooth face gear is orthogonal, and the included angle is α0Is acAt SpMiddle winding ypThe initial angle of rotation.
As a preferable mode, the movement law of the disc-shaped cutter is set to comprise three translational displacements and one corner displacement; the three translations are: sPRelative to S2At x2、y2、z2Is represented by displacement X, Y, Z as:
Figure BDA0002441016080000021
wherein the angular displacement is
Figure BDA0002441016080000022
Is ScAt SpMiddle winding ypAngular displacement of rotation, being an independent processing parameter, NsIs the number of teeth of the imaginary involute generating wheel.
As a preferred way, designing the disc cutter comprises the following steps:
① the shape-generating line of the plane of the cutter body is perpendicular to the axis of the disc cutter and has a length rc，2.5m≤rc≤4m；
② the line of the conical surface intersects the line of the planar surface of the cutter body at a point u0 from the midpoint of the line of the conical surface and u0＝1.25m/cosαcThe included acute angle between the conical surface shape generating line and the cutter body plane shape generating line is αc，15°≤αc≤45°；
③ Cone shape-producing line midpoint to disc cutter coordinate plane xcOcycIs 0.25 pi m;
④ the disk cutter is divided into one side conical surface and two side conical surfaces, the generating surface of the disk cutter in the case of single side conical surface is composed of a straight line passing through the center of the disk cutter and intersecting with the generating line of conical surface and being parallel to the generating line of cutter body plane, the generating line of cutter body plane and the generating line of conical surface, the generating surface of the disk cutter in the case of double side conical surface is composed of a straight line of generating line of cutter body plane, the generating line of conical surface and the two straight lines in the coordinate plane xcOcycA mirror image line of a plane of symmetry;
⑤ the disc cutter is divided into a cutting tool and a grinding tool, the cutting tool is made by making the generating surface of the cutting tool surround the axis Z of the disc cuttercRotating 360 degrees, uniformly forming 8-12 chip grooves on the conical surface, and radially distributing main cutting edges along the disc-shaped cutter; the manufacturing method of the grinding cutter comprises the following steps: with tool-defining surfaces about the disc-tool axis ZcRotating 360 degrees, and covering the grinding material on the conical surface;
the conic equation of the disc cutter according to the steps of firstly to fifthly can be expressed as follows:
Figure BDA0002441016080000031
wherein psicIs the angle of rotation of the conical surface shape-producing line, and u is the distance from the moving point to the fixed point on the cutting edge;
seventhly, according to the initial position of the disc-shaped cutter, the motion rule of the disc-shaped cutter and the cone equation of the disc-shaped cutter, the cone family of the disc-shaped cutter in S2 is as follows:
Figure BDA0002441016080000032
as a preferred mode, the selected numerical control machine tool comprises three numerical control translational motion axes Nx、Ny、NzTwo numerically controlled rotary motion axes NA、NBAnd a free-wheeling axis of motion; three numerical control translational motion axes Nx、Ny、NzPerpendicular to each other, for setting the distance C of the initial position of the disc cutter, respectivelyx、Cy、CzAnd disc cutter translational displacement X, Y, Z; two numerically controlled rotary motion axes NA、NBPerpendicular to each other, one of the numerically controlled axes of rotary motion NAAn orthogonal straight tooth face gear workpiece is arranged on the upper part; another numerical control rotary motion shaft NBA free rotation motion shaft vertical to the upper fixed part; the disc cutter is mounted coaxially on a freely rotating shaft which provides the cutting motion during the machining of the workpiece.
As a preferred mode, writing a numerical control program includes the steps of:
① solving for angular displacement at the inner diameter of an orthogonal spur face gear
Figure BDA0002441016080000044
The solving formula is as follows:
Figure BDA0002441016080000041
solving for angular displacement at the outer diameter of an orthogonal straight-tooth face gear
Figure BDA0002441016080000045
The solving formula is as follows:
Figure BDA0002441016080000042
l1 and L2 are the inner and outer diameters of the orthogonal spur face gear, respectively.
② determining indexing movement, numerical control axis of rotation NAThe indexing rotation angle is as follows:
NAi＝(i-1)·360°/(N2-1)i＝1,2,3,…,N2；
③ determining the feed movement at tooth height, numerical control translational movement axis NzThe position relative to the origin of the machine tool is;
Nzj＝Cz+2.25m-j·2.25m/J j＝1,2,3,…,J；
wherein J is a positive integer greater than 1 in the rough cutting, semi-finish cutting, rough grinding and semi-finish grinding processing technologies, and 1 is taken from J in the finish cutting and finish grinding processing technologies;
④ determining numerical control rotational motion axis NBThe turning angle of (1) is:
Figure BDA0002441016080000043
wherein K is a positive integer between 20 and 30 in the rough cutting, semi-finish cutting, rough grinding and semi-finish grinding processing technology, and K is a positive integer between 30 and 120 in the finish cutting and finish grinding processing technology;
⑤ determining numerical control translational motion axis Nx、NyThe positions relative to the origin of the machine tool are respectively as follows:
Nxk＝Cx+rps·NBk
Figure BDA0002441016080000051
as a preferable mode, the face cutting gear comprises a disc-shaped cutter arranged on a numerical control machine tool, an orthogonal straight-tooth face gear workpiece arranged on the numerical control machine tool, a numerical control program input, a machine tool debugging, a tool setting, a machine tool starting, cutting, tool changing and grinding of the orthogonal straight-tooth face gear workpiece, and a numerical control translation motion shaft N is driven to translate after all the tooth faces on one side are cutyThe position of the machine tool relative to the original point is changed into reverse, and all the tooth surfaces on the other side are cut.
Compared with the prior art, the invention has the following advantages:
1. the disc-shaped cutter has a simple structure, and the cutter body and the conical surface are formed by simple linear rotation;
2. the conical surface of the disc-shaped cutter is in line contact with the processed tooth surface, so that the processing efficiency is high;
3. the machine tool can be processed on the existing three-linkage 5-axis numerical control machine tool, and a complex high-precision machine tool is not needed;
4. the tooth surface deviation is small, the roughness is low, and the smoothness is good;
5. the disc-shaped cutter has simple motion rule and does not need complex generating motion;
6. the cutting tool can be used for cutting and grinding orthogonal straight-tooth face gears;
drawings
FIG. 1 is a schematic diagram and relative positional relationship of a disc cutter for machining a spur face gear.
Fig. 2 profile of the disc cutter and parameters on the disc cutter.
The gear and disc cutter parameters for the embodiment of fig. 3.
The numerical simulation results of the tooth surface of the orthogonal straight tooth surface machined by the disc cutter of the embodiment of fig. 4 and the tooth surface machined by the gear shaping are obtained.
The numerical simulated deviations of the orthogonal spur toothed gear tooth surface from the gear shaping flank of the embodiment of fig. 5.
Wherein, 1 disk cutter, 2 face gears, 3 chip grooves, 4 cutter body plane shape generating lines and 5 conical surface shape generating lines.
Detailed Description
The invention will be further described with reference to the accompanying drawings. Embodiments of the present invention include, but are not limited to, the following examples.
Example 1:
referring to fig. 1-5, a machining method for manufacturing an orthogonal straight-tooth face gear 2 by using a disc-shaped cutter 1 is characterized by comprising the following steps: establishing a coordinate system, setting the initial position of the disc-shaped cutter 1, setting the motion rule of the disc-shaped cutter 1, designing the disc-shaped cutter 1, selecting a numerical control machine, compiling a numerical control program and cutting a face gear 2.
Referring to fig. 1, as a preferred mode, establishing the coordinate system includes: establishing a coordinate system S of an orthogonal straight face gear 22(x2y2z2O2) Wherein z is2Coincident with the axis of the orthogonal spur gear 2, S2Origin O of2The distance from the pitch cone surface of the orthogonal straight tooth face gear 2 is rps，rpsIs the radius of the reference circle of the imaginary involute profile wheel; establishing an auxiliary coordinate system Sp(xpypzpOp) Wherein x isp∥z2，yp∥y2，zp∥x2，SpRelative to S2Along x2、y2、z2Translating; establishing a coordinate system S of a disc cutter 1c(xcyczcOc) In which S iscOrigin O ofcAnd SpOrigin O ofpCoincidence, ycAnd ypCoincidence, ScOrigin O ofcIs the center of the disc cutter 1, z2Coinciding with the axis of the disc cutter 1, ScAt SpMiddle winding ypAnd (4) rotating.
Referring to fig. 1, as a preferred mode, the initial position of the disc cutter 1 is set to include three distances and an included angle, the three distances being: spRelative to S2At x2、y2、z2Distance C ofx、Cy、CzRespectively expressed as:
Cx＝-0.25·π·m·cos2α+u0·sinα-rc·sinα0，
Cy＝m·N2/2，
Cz＝0.25·π·m·cosα·sinα+u0·cosα+rc·cosα0-rps，
where m is the modulus, α is the pressure angle, rc、u0α, the distances from the intersection point of the conical surface shaping line 5 and the cutter body plane shaping line 4 of the disc cutter 1 to the axial line of the disc cutter 1 and the midpoint of the conical surface shaping line 50＝αc-α，αcThe inclination angle of the conical surface shape-generating line 5 of the disc-shaped cutter 1 is equal to the acute angle N between the conical surface shape-generating line 5 and the cutter plane shape-generating line 42Is the number of teeth of the orthogonal straight tooth face gear 2, and the included angle is α0Is acAt SpMiddle winding ypRotatingThe initial turning angle.
Referring to fig. 1, as a preferred mode, the motion rule of the disc-shaped cutter 1 is set to comprise three translational displacements and one corner displacement; the three translations are: sPRelative to S2At x2、y2、z2Is represented by displacement X, Y, Z as:
Figure BDA0002441016080000061
wherein the angular displacement is
Figure BDA0002441016080000062
Is ScAt SpMiddle winding ypAngular displacement of rotation, being an independent processing parameter, NsIs the number of teeth of the imaginary involute generating wheel.
Referring to fig. 1, as a preferred way to design a disc cutter comprises the following steps:
① cutter body plane generating line 4 is perpendicular to the axis of the disc cutter 1 and has a length rc，2.5m≤rc≤4m；
② Cone shape-producing line 5 intersects cutter body plane shape-producing line 4 at a point u from the midpoint of cone shape-producing line 50And u is0＝1.25m/cosαcThe included acute angle between the conical surface shape-generating line 5 and the cutter body plane shape-generating line 4 is αc，15°≤αc≤45°；
③ Cone shape-producing line 5 midpoint to disk cutter 1 coordinate plane xcOcycIs 0.25 pi m;
④ the disk-shaped cutter 1 is divided into two cases of a single side conical surface and a double side conical surface, the generating surface of the disk-shaped cutter 1 in the case of the single side conical surface is composed of a straight line passing through the center of the disk-shaped cutter 1 and intersecting with the conical surface generating line 5 and being parallel to the cutter body plane generating line 4, and the conical surface generating line 5, and the generating surface of the disk-shaped cutter 1 in the case of the double side conical surface is composed of a straight line of the cutter body plane generating line 4, the conical surface generating line 5 and the two straight lines in the coordinate plane xcOcycA mirror image line of a plane of symmetry;
⑤ the disc cutter is divided into a cutting tool and a grinding tool, the cutting tool is made by making the generating surface of the cutting tool surround the axis Z of the disc cutter 1cRotating 360 degrees, uniformly forming 8-12 chip grooves on the conical surface, and radially distributing main cutting edges along the disc-shaped cutter 1; the manufacturing method of the grinding cutter comprises the following steps: with tool-defining surfaces about the axis Z of its disc-shaped tool 1cRotating 360 degrees, and covering the grinding material on the conical surface;
the conic equation of the disc cutter according to the steps of firstly to fifthly can be expressed as follows:
Figure BDA0002441016080000071
wherein psicIs the angle of rotation of the conical surface shape-producing line 5, and u is the distance from the moving point to the fixed point on the cutting edge;
seventhly, according to the initial position of the disc-shaped cutter 1, the motion rule of the disc-shaped cutter 1 and the cone equation of the disc-shaped cutter 1, the cone family of the cone of the disc-shaped cutter 1 in S2 is:
Figure BDA0002441016080000072
referring to fig. 1, as a preferred mode, the numerically controlled machine tool comprises three numerically controlled translational motion axes Nx、Ny、NzTwo numerically controlled rotary motion axes NA、NBAnd a free-wheeling axis of motion; three numerical control translational motion axes Nx、Ny、NzPerpendicular to each other, for setting the distance C of the initial position of the disc cutter 1, respectivelyx、Cy、CzAnd the disc cutter 1 translational displacement X, Y, Z; two numerically controlled rotary motion axes NA、NBPerpendicular to each other, one of the numerically controlled axes of rotary motion NAA workpiece of an orthogonal straight tooth face gear 2 is arranged on the upper part; another numerical control rotary motion shaft NBA free rotation motion shaft vertical to the upper fixed part; the disc-shaped tool 1 is coaxially mounted on a freely rotating shaft which provides a cut during the machining of a workpieceA cutting motion.
Referring to fig. 1, as a preferred mode, writing a numerical control program includes the steps of:
① solving for the angular displacement at the inner diameter of the spur face gear 2
Figure BDA0002441016080000084
The solving formula is as follows:
Figure BDA0002441016080000081
solving the angular displacement at the outer diameter of the orthogonal straight-tooth face gear 2
Figure BDA0002441016080000085
The solving formula is as follows:
Figure BDA0002441016080000082
l1 and L2 are the inner diameter and the outer diameter of the spur face gear 2, respectively.
② determining indexing movement, numerical control axis of rotation NAThe indexing rotation angle is as follows:
NAi＝(i-1)·360°/(N2-1)i＝1,2,3,…,N2；
③ determining the feed movement at tooth height, numerical control translational movement axis NzThe position relative to the origin of the machine tool is;
Nzj＝Cz+2.25m-j·2.25m/J j＝1,2,3,…,J；
wherein J is a positive integer greater than 1 in the rough cutting, semi-finish cutting, rough grinding and semi-finish grinding processing technologies, and 1 is taken from J in the finish cutting and finish grinding processing technologies;
④ determining numerical control rotational motion axis NBThe turning angle of (1) is:
Figure BDA0002441016080000083
wherein K is a positive integer between 20 and 30 in the rough cutting, semi-finish cutting, rough grinding and semi-finish grinding processing technology, and K is a positive integer between 30 and 120 in the finish cutting and finish grinding processing technology;
⑤ determining numerical control translational motion axis Nx、NyThe positions relative to the origin of the machine tool are respectively as follows:
Nxk＝Cx+rps·NBk
Figure BDA0002441016080000091
referring to fig. 1, as a preferred mode, the face gear cutting comprises the steps of installing a disc-shaped cutter 1 on a numerical control machine tool, installing a workpiece of an orthogonal straight-tooth face gear 2, inputting a numerical control program, debugging the machine tool, setting a tool, starting the machine tool, cutting, changing the tool, grinding the workpiece of the orthogonal straight-tooth face gear 2 and the like, wherein the steps are the same as the conventional processing steps of the face gear 2, and after all tooth surfaces on one side are cut, a numerical control translational motion shaft N is driven to move until all tooth surfaces on one side are cutyThe position of the machine tool relative to the original point is changed into reverse, and all the tooth surfaces on the other side are cut.
Fig. 3 shows parameters for a given set of orthogonal spur face gears 2, fig. 4 shows the results of numerical simulation calculations for the proposed method for machining orthogonal spur face gears 2 with the disc cutter 1 according to the above method, respectively showing the tooth surface of the orthogonal spur face gear 2 machined with the disc cutter 1 and the tooth surface of the orthogonal spur face gear 2 machined with the slotting, and fig. 5 shows the deviations between the numerically simulated tooth surfaces for two different machining directions, the maximum deviation of the working tooth surface portion being only 82.6 μm, which is less than one tenth of the tooth surface deviation of the tooth surface machined with the gritson face cutter, and therefore, the tooth surface accuracy is greatly improved.
The above is an embodiment of the present invention. The embodiments and specific parameters in the embodiments are only used for clearly illustrating the verification process of the invention and are not used for limiting the patent protection scope of the invention, which is defined by the claims, and all the equivalent structural changes made by using the contents of the description and the drawings of the present invention should be included in the protection scope of the present invention.

Claims (8)

1. A machining method for manufacturing an orthogonal straight-toothed face gear (2) by a disc cutter (1), characterized by comprising the following steps: establishing a coordinate system, setting the initial position of the disc-shaped cutter (1), setting the motion rule of the disc-shaped cutter (1), designing the disc-shaped cutter (1), selecting a numerical control machine, writing a numerical control program and cutting a face gear (2).
2. The method of claim 1, wherein the disc cutter is used to manufacture orthogonal spur gears, and wherein: establishing the coordinate system comprises the following steps: establishing a coordinate system S of an orthogonal straight-toothed gear (2)2(x2y2z2O2) Wherein z is2Coincident with the axis of the orthogonal spur gear 2, S2Origin O of2The distance from the pitch cone surface of the orthogonal straight tooth face gear (2) is rps，rpsIs the radius of the reference circle of the imaginary involute profile wheel; establishing an auxiliary coordinate system Sp(xpypzpOp) Wherein x isp∥z2，yp∥y2，zp∥x2，SpRelative to S2Along x2、y2、z2Translating; establishing a coordinate system S of the disc-shaped tool (1)c(xcyczcOc) In which S iscOrigin O ofcAnd SpOrigin O ofpCoincidence, ycAnd ypCoincidence, ScOrigin O ofcIs the center of the disc cutter (1), z2Coincides with the axis of the disc cutter (1), ScAt SpMiddle winding ypAnd (4) rotating.
3. The machining method for manufacturing an orthogonal straight-toothed gear by using the disc cutter as set forth in claim 2, wherein: setting the initial position of the disc cutter (1) comprises three distances and an included angle, wherein the three distances are respectively as follows: spRelative to S2At x2、y2、z2Distance C ofx、Cy、CzRespectively expressed as:
Cx＝-0.25·π·m·cos2α+u0·sinα-rc·sinα0，
Cy＝m·N2/2，
Cz＝0.25·π·m·cosα·sinα+u0·cosα+rc·cosα0-rps，
where m is the modulus, α is the pressure angle, rc、u0Respectively the distance from the intersection point of the conical surface shape-generating line (5) of the disc-shaped cutter (1) and the cutter body plane shape-generating line (4) to the central point of the axis of the disc-shaped cutter (1) and the conical surface shape-generating line (5), α0＝αc-α，αcThe inclination angle of the conical surface shape-generating line (5) of the disc-shaped cutter (1) is equal to the acute angle N between the conical surface shape-generating line (5) and the cutter body plane shape-generating line (4)2Is the number of teeth of the orthogonal straight tooth face gear (2) and has an included angle of α0Is acAt SpMiddle winding ypThe initial angle of rotation.
4. The machining method for manufacturing an orthogonal straight-toothed gear by using the disc cutter as set forth in claim 3, wherein: setting the motion rule of the disc-shaped cutter (1) to comprise three translational displacements and one corner displacement; the three translations are: sPRelative to S2At x2、y2、z2Is represented by displacement X, Y, Z as:
Figure FDA0002441016070000021
Z＝0，
wherein the angular displacement is
Figure FDA0002441016070000022
Is ScAt SpMiddle winding ypAngular displacement of rotation, being an independent processing parameter, NsIs the number of teeth of the imaginary involute generating wheel.
5. The machining method for manufacturing an orthogonal straight-toothed gear by using the disc cutter as set forth in claim 4, wherein: designing a disc cutter comprises the steps of:
① the cutter plane generating line (4) is vertical to the axis of the disc cutter (1) and has a length rc，2.5m≤rc≤4m；
② the conical shape-generating line (5) intersects the cutter body plane shape-generating line (4) at a point which is u away from the midpoint of the conical shape-generating line (5)0And u is0＝1.25m/cosαcThe included acute angle between the conical surface shape-generating line (5) and the cutter body plane shape-generating line (4) is αc，15°≤αc≤45°；
③ center point of conical surface forming line (5) to coordinate plane x of disc cutter (1)cOcycIs 0.25 pi m;
④ the disk-shaped cutter (1) is divided into a single-side conical surface and a double-side conical surface, the generating surface of the disk-shaped cutter (1) in the single-side conical surface is composed of a straight line which passes through the center of the disk-shaped cutter (1), intersects with the conical surface generating line (5) and is parallel to the cutter body plane generating line (4), the cutter body plane generating line (4) and the conical surface generating line (5), and the generating surface of the disk-shaped cutter (1) in the double-side conical surface is composed of a straight line which passes through the center of the disk-shaped cutter (1), intersects with the conical surface generating line (5) and is parallel to the cutter body plane generating line (4), the cuttercOcycA mirror image line of a plane of symmetry;
⑤ the disc cutter is divided into a cutting tool and a grinding tool, the cutting tool is made by making the generating surface of the cutting tool surround the axis Z of the disc cutter (1)cRotating 360 degrees, uniformly forming 8-12 chip grooves on the conical surface, and radially distributing main cutting edges along the disc-shaped cutter (1); the manufacturing method of the grinding cutter comprises the following steps: the tool-forming surface is made to surround the axis Z of the disc-shaped tool (1)cRotating 360 degrees, and covering the grinding material on the conical surface;
the conic equation of the disc cutter according to the steps of firstly to fifthly can be expressed as follows:
Figure FDA0002441016070000023
wherein psicIs the angle of rotation of the conical surface shape-generating line (5), and u is the distance from the moving point to the fixed point on the cutting edge;
seventhly, according to the initial position of the disc-shaped cutter (1), the motion rule of the disc-shaped cutter (1) and the cone equation of the disc-shaped cutter (1), the cone group of the cone of the disc-shaped cutter (1) in S2 is as follows:
Figure FDA0002441016070000031
6. the machining method for manufacturing an orthogonal straight-toothed gear by using the disc cutter as set forth in claim 4, wherein: the numerical control machine tool comprises three numerical control translational motion axes Nx、Ny、NzTwo numerically controlled rotary motion axes NA、NBAnd a free-wheeling axis of motion; three numerical control translational motion axes Nx、Ny、NzPerpendicular to each other, for setting the distance C of the initial position of the disc cutter (1) respectivelyx、Cy、CzAnd a translational displacement X, Y, Z of the disc cutter (1); two numerically controlled rotary motion axes NA、NBPerpendicular to each other, one of the numerically controlled axes of rotary motion NAA workpiece of an orthogonal straight tooth face gear (2) is arranged on the upper part; another numerical control rotary motion shaft NBA free rotation motion shaft vertical to the upper fixed part; the disc cutter (1) is coaxially mounted on a freely rotating shaft which provides the cutting movement during the machining of the workpiece.
7. The method of claim 6 wherein the disk cutter is used to manufacture orthogonal spur gears, the method comprising: the numerical control program writing method comprises the following steps:
① solving the angular displacement at the inner diameter of the orthogonal straight face gear (2)
Figure FDA0002441016070000035
The solving formula is as follows:
Figure FDA0002441016070000032
solving the angular displacement at the outer diameter of the orthogonal straight tooth face gear (2)
Figure FDA0002441016070000033
The solving formula is as follows:
Figure FDA0002441016070000034
l1 and L2 are the inner diameter and the outer diameter of the orthogonal spur gear (2), respectively.
② determining indexing movement, numerical control axis of rotation NAThe indexing rotation angle is as follows:
NAi＝(i-1)·360°/(N2-1) i＝1,2,3,…,N2；
③ determining the feed movement at tooth height, numerical control translational movement axis NzThe position relative to the origin of the machine tool is;
Nzj＝Cz+2.25m-j·2.25m/J j＝1,2,3,…,J；
wherein J is a positive integer greater than 1 in the rough cutting, semi-finish cutting, rough grinding and semi-finish grinding processing technologies, and 1 is taken from J in the finish cutting and finish grinding processing technologies;
④ determining numerical control rotational motion axis NBThe turning angle of (1) is:
Figure FDA0002441016070000041
wherein K is a positive integer between 20 and 30 in the rough cutting, semi-finish cutting, rough grinding and semi-finish grinding processing technology, and K is a positive integer between 30 and 120 in the finish cutting and finish grinding processing technology;
⑤ determining numerical control translational motion axis Nx、NyThe positions relative to the origin of the machine tool are respectively as follows:
Nxk＝Cx+rps·NBk
Figure FDA0002441016070000042
8. a disc according to any one of claims 1 to 7The processing method for manufacturing the orthogonal straight tooth face gear by the profile cutter is characterized by comprising the following steps of: the cutting face gear (2) comprises a disc-shaped cutter (1) arranged on a numerical control machine tool, an orthogonal straight-tooth face gear (2) workpiece arranged on the numerical control machine tool, a numerical control program input, a machine tool debugging, a tool setting, a machine tool starting, a cutting, a tool changing and an orthogonal straight-tooth face gear (2) workpiece grinding until all tooth faces on one side are cut, and a numerical control translation motion shaft N is driven to translateyThe position of the machine tool relative to the original point is changed into reverse, and all the tooth surfaces on the other side are cut.
CN202010265204.3A 2020-04-07 2020-04-07 Machining method for manufacturing orthogonal straight-tooth face gear by disc-shaped cutter Expired - Fee Related CN111515469B (en)

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