CN112439951A - Gear chamfering and milling method based on geometric adaptive compensation - Google Patents
Gear chamfering and milling method based on geometric adaptive compensation Download PDFInfo
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- B23F—MAKING GEARS OR TOOTHED RACKS
- B23F19/00—Finishing gear teeth by other tools than those used for manufacturing gear teeth
- B23F19/10—Chamfering the end edges of gear teeth
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Abstract
The invention discloses a milling method for a gear radius chamfer based on geometric adaptive compensation, which is characterized by completing clamping of a gear part under a rough reference, combining with on-machine measurement to detect the actual clamping state and position of the gear part, calculating the clamping error of the gear part according to the result of measurement data, determining the angular position of a gear aiming at a spiral bevel gear, adjusting a machining tool path or a machining coordinate system, and completing the milling of a fillet or a chamfer.
Description
Technical Field
The invention relates to the field of gear tooth crest and tooth profile chamfering, in particular to a gear chamfering milling method based on geometric adaptive compensation.
Background
The spiral bevel gear is used as a key transmission component in an aircraft engine, and has the advantages of high transmission efficiency, stable transmission ratio, large arc overlapping coefficient, high bearing capacity, reliable work, compact structure, wear resistance, long service life, low noise and the like. The process of chamfering the tooth tops and tooth profiles of the spiral bevel gears is very important to the transmission performance and the service life of the gears, and the process aims of chamfering the spiral bevel gears mainly include eliminating sharp corners and sharp edges to prevent scratches on tooth surfaces, reducing noise and impact force of gear transmission to improve transmission stability and reducing stress concentration to prolong the service life of the gears.
The chamfering and chamfering processing of the gear is widely applied to transmission gears and transmission gears in the industries of automobiles, aerospace and the like, the existing gear chamfering and chamfering processing technology is mainly directed to a standard straight gear, a special gear chamfering machine (gear chamfering machine) with mature technology is arranged on the market, the machine tool can perform high-speed chamfering and chamfering processing on the end part of the gear tooth of the gear, the gear chamfering machine is generally semi-automatic circulation, the workbench can perform unequal feeding, and the gear chamfering and chamfering processing machine is processing equipment indispensable for producing gear transmissions and other gear transmission mechanisms. However, in the aerospace field, because the gear transmission is required to have higher efficiency and better stability, spiral bevel gears with large arc overlapping coefficients are often adopted for transmission, and for the rounding and chamfering treatment of the spiral bevel gears, the manual grinding mode is mainly adopted for processing in the industry at present, and a skilled fitter is required to hold a high-speed grinding head by hand to round and chamfer each edge of the gear.
The special chamfering machine for the straight gear chamfering is not suitable for the chamfering of spiral bevel gears in the aerospace field, the existing manual polishing technology has high requirement on the skill level of operators, skilled bench workers are needed, the manual polishing consistency is poor, the processing quality is unstable, in addition, the manual polishing efficiency is low, and the manual polishing workload and the labor intensity for gear parts which need to be produced in large batches are high.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a gear radius chamfer milling method based on geometric adaptive compensation, which has high processing efficiency and high processing precision.
In order to solve the technical problems, the invention adopts the following technical scheme:
a gear chamfering and chamfering milling method based on geometric adaptive compensation comprises the following steps:
s1, taking a gear mounting datum plane as a Z-direction datum of a machining coordinate system, taking the center of an excircle of a gear mounting datum plane as an original point and a Z-axis axial direction of the machining coordinate system, and taking the middle part of an addendum as an angular rough datum of the gear, and clamping and positioning the gear at the machining center of the five-axis numerical control machine tool;
s2, determining the actual position of the gear in a machining coordinate system of a machine tool through on-machine measurement, determining a working plane and a coordinate origin of the rounding chamfer machining, uniformly selecting a plurality of teeth as measuring teeth along the circumferential direction of the gear, uniformly selecting a plurality of measuring points along the tooth surfaces at two sides of the measuring teeth, and determining the angular reference of the gear;
s3, setting measurement parameters according to the preset requirements, collecting the measurement results, and calculating the coordinate value P of the gear tooth surface measurement point according to the coordinate value of the measuring head ball pointi；
S4, coordinate value P based on gear tooth surface measuring pointiCoordinate value P 'of theoretical point corresponding to gear tooth surface measurement point'iCalculating to obtain rigid body transformation A between the actual clamping position and the theoretical clamping position of the gear;
s5 finding the knife point P according to the theorybcpVector of sum cutter axistovCalculating the cutter location point P 'in the actual cutter path by rigid body transformation A between the actual clamping position and the theoretical clamping position of the gear'bcpAnd knife axis vector'tovObtaining a self-adaptive compensated tool path track at the actual clamping position;
and S6, carrying out post-processing on the self-adaptive compensated tool path to obtain an NC code, and carrying out NC code adjustment machining tool path or coordinate system adjustment on the five-axis numerical control machine tool to carry out rounding chamfer milling machining on the gear.
As a further improvement to the above technical solution:
in the step S4, by minimizing the difference of the distance F between the measurement point and the theoretical point, a nonlinear least square problem of the gear clamping error is constructed and solved according to the formula (I), and the rigid body transformation a between the actual clamping position and the theoretical clamping position of the gear is calculated;
in the step S5, the cutter location point in the actual cutter path is calculated to be P 'according to the formula (II) and the formula (III)'bcpCutter axis vector of'tovObtaining a self-adaptive compensated tool path track at the actual clamping position;
P′bcp＝A-1·Pbcp (II)
V′tov＝A-1·tov (III)
in step S3, the coordinate value (x) of the probe ball tip point is usedtip,ytip,ztip) Calculating coordinate value (x) after radius compensationtouch,ytouch,ztouchThe coordinate value is the coordinate value P of the gear tooth surface measuring pointi。
The measurement parameter comprises a backoff distance dtA safety distance dsSearch distance daDetecting feed FpFast feed Fq。
The step S3 retreats by a distance dtThe distance from the measuring head to the safe height after the measurement is finished is measured; safety distance dsThe distance from a close point to a measuring point when the measuring head starts to move and measure is measured; search distance daWhen the measuring head moves to the position of the measuring point, the distance which is not contacted with the workpiece but is allowed to continue searching and detecting is obtained; detecting feed FpThe measuring head moving speed is measured; fast feed FqWhich refers to the moving speed of the stylus in a non-measuring state.
The step S1 is preceded by the following preparation:
a1, creating a solid model of the gear part according to the design parameters of the gear;
a2, establishing a processing tool path by adopting a fixed contour milling processing method, and selecting a tool which is in point contact with the processing surface of the gear part as a processing tool;
a3, selecting a machine measuring head according to a preset precision requirement, and determining a clamp for clamping the gear according to the structure of the gear workpiece and a preset machining standard.
The gear is a spiral bevel gear.
Compared with the prior art, the invention has the advantages that:
the invention relates to a milling method for chamfering and chamfering spiral bevel gears based on geometric self-adaptation, which is characterized in that a gear part is clamped on a machining center of a five-axis numerical control machine tool, the shape and position information of the gear is acquired in time and a two-position integration of machining and detection (as shown in figure 6) is realized by combining an on-machine measurement technology, the processing of measurement data is not required to be carried out by third-party software, the rapid clamping and alignment of the gear is realized by adjusting a machining tool path in geometric self-adaptation, the milling of the chamfering and chamfering of the gear (not limited to an addendum but also suitable for a tooth profile) is completed by utilizing the characteristics of high efficiency and high precision of the five-axis numerical control machine tool, the quality stability of the chamfering and the machining of the gear can be ensured, the machining efficiency can be effectively improved, the invention is.
Drawings
FIG. 1 is a process flow diagram of the present invention.
FIG. 2 is a schematic illustration of the location of the datum A, C of the present invention.
FIG. 3 is a schematic view of the clamping of the gear component of the present invention.
Fig. 4 is a schematic diagram of the location of the measurement points of the present invention.
FIG. 5 is a schematic of the measured parameters of the present invention.
FIG. 6 is a schematic diagram of the on-machine measurement of the present invention.
Detailed Description
The invention will be described in further detail below with reference to the drawings and specific examples. Unless otherwise specified, the instruments or materials employed in the present invention are commercially available.
Example 1:
the gear radius chamfer milling method based on geometric adaptive compensation of the embodiment has the following basic scheme: the method comprises the following steps of finishing clamping of the gear part under a rough reference, detecting the actual clamping state and position of the gear part by combining on-machine measurement, calculating the clamping error of the gear part according to the result of measurement data, determining the angular position of the gear according to the spiral bevel gear, adjusting a machining tool path or a machining coordinate system, and finishing the milling of a fillet or a chamfer, wherein the machining flow chart is shown in figure 1:
(1) preparation before processing
The processing method of the spiral bevel gear radius chamfer is fixed profile milling processing carried out under a five-axis numerical control machine tool, therefore, related preparation work is required to be carried out before the upper machine tool carries out processing, and the preparation mainly comprises preparation of a gear digital model, cutter path programming, a cutter scheme, a clamp scheme and the like;
a) preparation of gear digital model: in UG or other three-dimensional CAD software, a solid model of the gear part is created according to design parameters of the gear, so that subsequent fillet and chamfer characteristics are created and tool path programming is processed conveniently;
b) preparation of a processing tool path and a cutter: the fillet and chamfer characteristics of the spiral bevel gear are free curved surface characteristics with good openness, a processing tool path of the rounding chamfer can be created by adopting a processing method of fixed profile milling, in addition, because the fillet surface is a free curved surface, the contact between a tool and a processing surface is point contact, a ball head tool is considered and selected as a tool for rounding chamfer processing, the length L and the diameter D of the tool and relevant technological parameters such as the main shaft rotating speed S, the feed rate F and the like are specified, generally, L can be selected to be about 100mm, D can be selected to be about 4mm, S can be selected to be about 8000r/min, and F can be selected to be about 1000 mm/min;
c) preparation of the jig and the machine probe: according to the structure appearance of gear parts and the machining reference that design drawing markd, reasonable in design and with gear parts matched with anchor clamps are used in gear radius chamfer processing, in this application, the anchor clamps that clamping spiral awl tooth used are three-jaw chuck commonly used in machining, and its main component is chuck and three jack catch, for effectively guaranteeing the reliability of clamping, need adopt the chuck of high accuracy. In addition, because the processing method in the invention needs to be combined with an on-machine measurement technology, an on-machine probe with sufficient precision (a high-precision probe for measuring 3D anisotropy +/-1 um within 0.5um of measurement repeatability) needs to be selected, and generally, an OMP400/600 series in Renysha can be adopted;
(2) determining a rough reference of clamping according to a gear design drawing
a) Determining a plane reference of the gear by referring to a design drawing, wherein a plane where a gear mounting reference surface (reference C) is located can be used as a Z-direction reference of a machining coordinate system;
b) according to a design drawing, the center of the outer circle of the gear installation (the axis of the outer cylindrical surface where the reference A is located) can be used as the origin of a machining coordinate system and the axial direction of a Z axis, and the positions of the reference A and the reference C are shown in FIG. 2;
c) because the forming machining of the spiral bevel gear is carried out in a mode of milling and grinding generating machining, no angular reference exists, the middle position of an addendum can be preliminarily selected as an angular rough reference of the gear, only the requirement that a measuring head does not interfere with a workpiece when measuring under the rough reference is met, and then the accurate angular reference of the gear is determined through on-machine measurement;
(3) finish the preliminary positioning and clamping of the gear part on the five-axis machining center
And (3) positioning and clamping the gear workpiece on a machining center of the five-axis numerical control machine tool according to the rough reference determined in the previous step and the designed special fixture, wherein the clamping effect is as shown in figure 3.
(4) Determination of actual position of gear part under machining coordinate system of five-axis numerical control machine tool through on-machine measurement
a) According to the design drawing of the gear, the working plane and the coordinate origin of the chamfering and milling process of the rounding chamfer can be accurately determined on a machine tool through a positioning device of a fixture, but the angular reference of the gear cannot be accurately determined, so that a measurement path for determining the angular reference of the gear needs to be planned, in order to accurately reflect the angular deviation of the gear, about 5 measurement points are uniformly distributed on tooth surfaces on two sides of the gear, and about 4 teeth are uniformly selected in the circumferential direction of the gear for measurement, as shown in fig. 4, the rotation angle around the Z axis of a processing coordinate system is calculated according to measurement result data, and the position of the angular reference can be obtained.
b) Setting a measurement-related parameter, the backoff distance dtA safety distance dsSearch distance daDetecting feed FpFast feed Fq(ii) a Wherein, the distance d is reversedtThe distance from the measuring head to the safe height after the measurement is finished is measured; safety distance dsThe distance from a close point to the surface of a workpiece when a measuring head starts to move and measure is referred to; search distance daWhen the measuring head moves to the planned surface position of the workpiece, the measuring head still does not contact the workpiece, and the detection distance is allowed to be searched continuously, as shown in fig. 5; detecting feed FpThe measuring head moving speed is measured; fast feed FqWhich is the moving speed of the stylus in a non-measuring state (i.e., idle running state).
c) Collecting measurement result, extracting measurement result file from numerical control system, and processing related format, wherein the measurement result stored in the numerical control system is generally coordinate value (x) of probe ball pointtip,ytip,ztip) Before the next calculation, the radius compensation of the measuring head sphere is needed to obtain the measuring head contact point, namely the actual measuring point PiCoordinate value (x) oftouch,ytouch,ztouch). The measuring head sphere radius compensation specifically comprises the following steps: and translating the measuring head ball point along the measuring needle axial direction by a radius value of the measuring head to obtain a measuring head ball center point, and then projecting the ball center point to the gear model curved surface to obtain a measuring head contact point.
The on-line measurement schematic diagram of the application is shown in fig. 6, and measurement software of an upper computer is in communication connection with a numerical control system (CNC) through an Ethernet; RMI is a combined device of an interface and a receiving unit, is matched with a measuring head and is in communication connection with a CNC (computer numerical control) system through Ethernet; the servo system is used for realizing the feeding servo control and the main shaft servo control of the numerical control machine tool, and converting the received instruction information from the numerical control device into linear displacement or angular displacement motion of a machine tool execution part after power amplification and shaping treatment; and the measurement software of the upper computer transmits the measurement path obtained by the servo system to a CNC (computer numerical control) system to generate a measurement program, the measurement program is transmitted to the CNC to be executed, and after the measurement is finished, the measurement software of the upper computer acquires measurement result data from the CNC system.
(5) Calculating the clamping error of the gear under the rough reference
a) The measured value P of the gear tooth surface measuring point can be obtained through the step (4)iLet its corresponding theoretical point be P'iAssuming that the rigid body corresponding to the clamping error is converted into A, constructing a nonlinear least square problem for solving the clamping error of the gear by minimizing the point-point distance difference between the actual point and the theoretical point
The rigid body transformation A from the actual clamping position to the expected theoretical clamping position of the gear can be obtained by solving the nonlinear least square problem.
b) Selecting a method for solving the least square problem, wherein the invention adopts a Levenberg-Marquardt method to solve the nonlinear least square problem, the method is an iterative calculation method, before calculation, the partial derivative and Jacobian matrix of an objective function F to an optimization variable need to be solved, and a proper iteration initial value A is selected0(generally, the initial value a0 is I, and I is a rigid transformation identity matrix), and then the rigid transformation a is obtained by solving based on a mathematical tool, and the transformation can be regarded as a position transformation corresponding to the gear clamping error.
(6) Position error compensation for gear chamfering
a) The error transformation A between the current actual clamping position and the expected theoretical clamping position of the gear can be obtained through the step (5), and the cutter position point in the theoretically planned cutter path is assumed to be pbcpThe vector of the cutter axis is VtovAnd applying the transformation A to the theoretical cutter path to obtain the actual compensated cutter path.
b) Suppose that the blade position point in the actual blade path is P'bcpThe knife axis vector is V'tovP 'can be calculated'bcp＝A-1·PbcpSame is V'tov＝A-1·VtovAnd obtaining the self-adaptive rear tool path track at the actual clamping position.
(7) Post-processing and milling processing of processing tool path
And (4) carrying out post-processing on the tool path after the self-adaptive compensation obtained in the step (6) to obtain an NC code, and sending the NC code to a five-axis numerical control machine tool for execution to finish the milling processing of the rounding chamfer of the spiral bevel gear.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make numerous possible variations and modifications to the present invention, or modify equivalent embodiments to equivalent variations, without departing from the scope of the invention, using the teachings disclosed above. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention should fall within the protection scope of the technical scheme of the present invention, unless the technical spirit of the present invention departs from the content of the technical scheme of the present invention.
Claims (8)
1. A gear radius chamfer milling method based on geometric adaptive compensation is characterized in that: the method comprises the following steps:
s1, taking a gear mounting datum plane as a Z-direction datum of a machining coordinate system, taking the center of an excircle of a gear mounting datum plane as an original point and a Z-axis axial direction of the machining coordinate system, and taking the middle part of an addendum as an angular rough datum of the gear, and clamping and positioning the gear at the machining center of the five-axis numerical control machine tool;
s2, determining the actual position of the gear in a machining coordinate system of a machine tool through on-machine measurement, determining a working plane and a coordinate origin of the rounding chamfer machining, uniformly selecting a plurality of teeth as measuring teeth along the circumferential direction of the gear, uniformly selecting a plurality of measuring points along the tooth surfaces at two sides of the measuring teeth, and determining the angular reference of the gear;
s3, setting measurement parameters according to preset requirements, collecting measurement results, and calculating according to coordinate values of the measuring head ball point to obtain the gearCoordinate value P of tooth surface measuring pointi；
S4, coordinate value P based on gear tooth surface measuring pointiCoordinate value P 'of theoretical point corresponding to gear tooth surface measurement point'iCalculating to obtain rigid body transformation A between the actual clamping position and the theoretical clamping position of the gear;
s5 finding the knife point P according to the theorybcpSum arbor vector VtovCalculating the cutter location point P 'in the actual cutter path by rigid body transformation A between the actual clamping position and the theoretical clamping position of the gear'bcpAnd a cutter shaft vector V'tovObtaining a self-adaptive compensated tool path track at the actual clamping position;
and S6, carrying out post-processing on the self-adaptive compensated tool path to obtain an NC code, and carrying out NC code adjustment machining tool path or coordinate system adjustment on the five-axis numerical control machine tool to carry out rounding chamfer milling machining on the gear.
2. The processing method according to claim 1, characterized in that: in the step S4, by minimizing the difference of the distance F between the measurement point and the theoretical point, a nonlinear least square problem of the gear clamping error is constructed and solved according to the formula (I), and the rigid body transformation a between the actual clamping position and the theoretical clamping position of the gear is calculated;
3. the processing method according to claim 1, characterized in that: in the step S5, the cutter location point in the actual cutter path is calculated to be P 'according to the formula (II) and the formula (III)'bcpThe knife axis vector is V'tovObtaining a self-adaptive compensated tool path track at the actual clamping position;
P′bcp＝A-1·Pbcp(II)
V′tov＝A-1·Vtov(III)。
4. the processing method according to claim 1, characterized in that: in step S3, the coordinate value (x) of the probe ball tip point is usedtip，ytip，ztip) Calculating coordinate value (x) after radius compensationtouch，ytouch，ztouch) The coordinate value is the coordinate value P of the gear tooth surface measuring pointi。
5. The processing method according to claim 1, characterized in that: the measurement parameter comprises a backoff distance dtA safety distance dsSearch distance daDetecting feed FpFast feed Fq。
6. The processing method according to claim 5, characterized in that: the step S3 retreats by a distance dtThe distance from the measuring head to the safe height after the measurement is finished is measured; safety distance dsThe distance from a close point to a measuring point when the measuring head starts to move and measure is measured; search distance daWhen the measuring head moves to the position of the measuring point, the distance which is not contacted with the workpiece but is allowed to continue searching and detecting is obtained; detecting feed FpThe measuring head moving speed is measured; fast feed FqWhich refers to the moving speed of the stylus in a non-measuring state.
7. The processing method according to claim 1, characterized in that: the step S1 is preceded by the following preparation:
a1, creating a solid model of the gear part according to the design parameters of the gear;
a2, establishing a processing tool path by adopting a fixed contour milling processing method, and selecting a tool which is in point contact with the processing surface of the gear part as a processing tool;
a3, selecting a machine measuring head according to a preset precision requirement, and determining a clamp for clamping the gear according to the structure of the gear workpiece and a preset machining standard.
8. The processing method according to claim 1, characterized in that: the gear is a spiral bevel gear.
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