CN113145944A - Vibration generating mechanism of gear lapping device - Google Patents
Vibration generating mechanism of gear lapping device Download PDFInfo
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- CN113145944A CN113145944A CN202110608294.6A CN202110608294A CN113145944A CN 113145944 A CN113145944 A CN 113145944A CN 202110608294 A CN202110608294 A CN 202110608294A CN 113145944 A CN113145944 A CN 113145944A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23F—MAKING GEARS OR TOOTHED RACKS
- B23F19/00—Finishing gear teeth by other tools than those used for manufacturing gear teeth
- B23F19/02—Lapping gear teeth
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23F—MAKING GEARS OR TOOTHED RACKS
- B23F23/00—Accessories or equipment combined with or arranged in, or specially designed to form part of, gear-cutting machines
Abstract
The invention belongs to the technical field of gear precision machining, and relates to a vibration generating mechanism of a gear lapping device. The mechanism provides main motion for the gear lapping device, and is matched with continuous meshing transmission of the gear and dynamic force in the grinding process to realize efficient and high-precision lapping of the gear tooth surface, so that the phenomenon that the tooth surface is not uniformly removed due to the traditional gear lapping transmission and grinding is effectively improved, the mechanism has the advantages of high grinding efficiency, obvious effect of improving the tooth surface machining precision and the like, and is particularly suitable for improving the machining precision after the fine grinding of a high-precision standard gear, a gear cutter and a transmission gear pair.
Description
Technical Field
The invention belongs to the technical field of gear precision machining, and relates to a vibration generating mechanism of a gear lapping device.
Background
The gears are important mechanical transmission parts, are widely applied to various aspects such as machine tools, smelting, aerospace, ship transportation, precision instruments, national defense and military industry and the like, and according to statistics, the number of the gears produced in the world every year is 2.5 hundred million, wherein the number of high-quality gears (the precision grade is IT 5 and above) is between 1000 and 1400 million, and the turnover exceeds 1000 hundred million euros. At present, gear cutting machining methods of gears mainly comprise gear hobbing, gear shaping and gear shaving, and the highest machining precision of the three machining methods is 5 grades; the gear grinding process can be used for processing high-precision gears, the highest processing precision is above grade 3, but the cost for processing the high-precision gears by the gear grinding process is high, and the processing limit is difficult to break through; the prior gear honing and lapping process mainly comprises the finishing processing of the gear to reduce the roughness of the tooth surface, but has limited improvement on the precision of the gear.
Patent (ZL201810466326.1) proposes a lapping device and a lapping method for gears based on the principle of error homogenization, which utilize the mutual lapping of high-precision gears meshed with each other to synchronously reduce the tooth pitch, tooth profile, spiral line and radial run-out deviation of the gear and obviously reduce the roughness of the tooth surface. Because the main motion of the grinding of the disclosed gear lapping device is the dynamic force in the meshing transmission and grinding process of the gears, the tooth surface sliding speed of the two lapping gears is gradually increased from a reference circle to the tooth top and the tooth bottom in the grinding process from zero, the tooth profile precision is lost due to long-time grinding, and in order to improve the lapping efficiency and the lapping precision of the gear lapping device, the lapping method of the original gear lapping device needs to be innovated.
Disclosure of Invention
In order to improve the lapping efficiency and the lapping precision of the gear lapping device, the invention provides a vibration generating mechanism of the gear lapping device, which drives a vibration generator by a stepping motor to generate opposite vibration of two lapping gears, and the opposite vibration is used as main motion of the gear lapping device and is matched with continuous meshing transmission of the gears to realize efficient and high-precision lapping of the gears.
The specific technical scheme is as follows:
a vibration generating mechanism for a gear lapping device comprises a vibration generator, a flange shaft, a coupler, a lapping gear A, a motor, a connecting rod A, a connecting rod B, a dense ball bearing, a gear mandrel, a lapping gear B, a spring, a rubber end cover A, a rubber end cover B, a connecting bolt A and a connecting bolt B;
the outer contour of the vibration generator is formed by smoothly connecting arc surfaces with equal radius, a circular hole is formed in the center of the vibration generator and is installed on a flange shaft, the flange shaft is connected with a motor through a coupler, and the motor rotates to drive the flange shaft and the vibration generator to synchronously rotate; triangular openings are formed in two opposite side surfaces of the connecting rod A and the connecting rod B, the vibration generator is arranged between the two openings, the top ends of the connecting rod A and the connecting rod B are fixed, gear mandrels are installed at the tail ends of the two connecting rods and are fixed by the connecting bolt A and the connecting bolt B respectively, dense ball bearings are installed in central holes of the two oppositely ground gears, and then the dense ball bearings are installed on the gear mandrels together; the length of the connecting bolt A and the connecting bolt B is greater than the thickness of the connecting rod A and the connecting rod B, the tail end of the connecting bolt A and the connecting bolt B is provided with a ring groove with the diameter larger than the diameter of the tension spring, and the two ends of the tension spring are connected by hooks; the two hooks are sleeved on the connecting bolt, and under the action of the tension spring, the two connecting rods are ensured to be in contact with the arc surface of the vibration generator or the two opposite grinding gears are meshed without backlash; under the rotation drive of the vibration generator, the two connecting rods synchronously swing along two symmetrical directions, the tooth surfaces of the two counter-grinding gears are subjected to reciprocating scratching and impacting, and materials in a relatively high point area of the tooth surfaces are slightly removed under the action of grinding agents, so that the purpose of correcting the machining precision of the tooth surfaces of the gears is achieved, the precision of the gears is improved, the effect of releasing machining stress is achieved, and the dimensional stability of the gears is enhanced.
Further, the number of the arc surfaces with the same radius of the multiple sections of the vibration generator is even, and the larger the number of the arc surfaces is, the larger the vibration frequency of the gear to be ground under the same rotation speed condition is.
Furthermore, when the included angle between the two connecting rods is the minimum value, the two opposite grinding gears are meshed without back clearance, and a proper clearance is reserved between the vibration generator and the two connecting rods; when the included angle of the two connecting rods is the maximum value, the vibration generator is contacted with the two connecting rods, and a proper back clearance is still left between the two oppositely grinding gears.
Further, the vibration generator is designed using the following formula:
in the formula, LmaxIs the maximum value of the swinging of the connecting rod in mm, LminThe distance between the initial position of the connecting rod and the rotation center of the vibration generator is in mm, the initial position refers to that two counter-grinding gears are in standard meshing, the center distance between the two gears is a standard center distance, namely d is mz, wherein m is the module of the gear to be ground, z is the number of teeth of the gear to be ground, l is the distance between the two ends of the circular arc and the rotation center of the vibration generator, r is the radius of the circular arc, mm is the unit, alpha is the corresponding central angle of the circular arc on vibration generation, degree is one n-th of 360 degrees, and n is the number of the circular arcs on the outer contour of the vibration generator.
Further, the frequency of the vibration generator is designed using the following formula:
f＝nN
in the formula, f is the swing frequency of the connecting rod, the unit Hz, N is the number of the outer contour arcs of the vibration generator, and N is the rotating speed of the vibration generator, and the unit rps.
Further, the connecting rod A and the connecting rod B are made of CGr15 bearing steel, and the hardness of the connecting rod A and the connecting rod B is not lower than HRC50 after quenching; the material of the vibration generator is a material having friction reducing properties to reduce wear of the vibration generator and the connecting rod.
The vibration generating mechanism of the gear lapping device has the advantages that lapping main motion is provided for the gear lapping device, efficient and high-precision lapping of the tooth surface of the gear is realized by matching with continuous meshing transmission of the gear and dynamic force in a grinding process, the phenomenon that the tooth surface is not uniformly removed due to traditional close gear meshing transmission grinding is effectively improved, the gear lapping mechanism has the advantages of high grinding efficiency, obvious effect of improving the tooth surface machining precision and the like, and is particularly suitable for improving the machining precision after fine grinding of a high-precision standard gear, a gear cutter and a transmission gear pair.
Drawings
FIG. 1 is a sectional view of a vibration generating mechanism of a gear lapping device.
FIG. 2 is an isometric view of a vibration generating mechanism of a gear lapping device.
Fig. 3 is a diagram of the vibration generator and the motion of two connecting rods.
Fig. 4 a vibration generator.
Fig. 5 shows the maximum limit position of the included angle between the two connecting rods.
Fig. 6 shows the minimum limit position of the included angle between the two connecting rods.
Fig. 7 is a schematic diagram of the design of the vibration generator.
In the figure: 1 a vibration generator; 2, a flange shaft; 3, coupling; 4 pairs of grinding gears A; 5 an electric motor; 6, a connecting rod A; 7, a connecting rod B; 8, a dense ball bearing; 9 a gear mandrel; 10 pairs of grinding gears B; 11 a tension spring; 12 rubber end cap A; 13 rubber end cap B; 14 connecting bolt A; 15 connecting bolt B.
Detailed Description
A vibration generating mechanism of a gear lapping device mainly comprises a vibration generator 1, a flange shaft 2, a coupler 3, a lapping gear A4, a motor 5, a connecting rod A6, a connecting rod B7, a dense ball bearing 8, a gear spindle 9, a lapping gear B10, a tension spring 11, a rubber end cover A12, a rubber end cover B13, a connecting bolt A14 and a connecting bolt B15.
A vibration generating mechanism of a gear lapping device is powered by a stepping motor to drive a vibration generator with even number of wave crests to rotate, and two connecting rods with fixed rotation centers are driven to synchronously swing along two symmetrical directions, so that the tooth surfaces of two lapping gears are reciprocally scratched and impacted. The amplitude of the swing of the connecting rod is adjusted by changing the size of the wave crest of the vibration generator; the swinging frequency of the connecting rod is adjusted by adjusting the rotating speed of the motor and the number of even wave crests of the vibration generator. The vibration generating mechanism is divided into two components according to different rotary shaft systems: vibration generator subassembly, gear and link assembly. A method of assembling and adjusting the vibration generating mechanism of the gear lapping device is described in detail below.
Firstly, (1) a method for assembling a vibration generator module in a vibration generating mechanism of a gear lapping device
A vibration generator component of a vibration generating mechanism of a gear lapping device comprises a vibration generator 1, a flange shaft 2, a coupling 3 and a motor 5. The motor 5 is a 57 step motor; the coupler 3 is a diaphragm elastic coupler made of aluminum alloy, and the diameter of an inner hole is 8 mm; the material for manufacturing the flange shaft 2 is 40Cr, the hardness of the material is HRC 45-50 after quenching, the material for manufacturing the vibration generator 1 is zinc white copper, the material has good wear resistance and hardness, a round hole with the diameter of 20mm is formed in the center of the material and is used for being installed in a corresponding shaft section of the flange shaft 2, small clearance fit is adopted, the clearance is about 2 mu m, the end face, in contact with the flange shaft 2, of the vibration generator 1 is a positioning face, the flatness of the face is required to be not more than 2 mu m, the vibration generator 1 is a quick-wear part, therefore, the vibration generator 1 needs to be replaced in time after being worn, and is fastened with the flange shaft 2 through bolts so as to be convenient to disassemble; because the vibration generator 1 is in rotary motion, each point on the outer contour is contacted with the connecting rod, the vibration generator 1 can be subjected to extrusion force in each direction, in order to be uniformly stressed and the abrasion loss of each position on the outer contour tends to be consistent, the maximum eccentricity of a central hole of the vibration generator 1 is required to be not more than 0.005mm, and meanwhile, the other benefit brought by controlling the eccentricity is that the deviation of the swing amplitude of the two gears and the connecting rod is small, so that in the gear lapping process, the abrasion of each position of the tooth surface of the gear to be lapped is uniform, the gear lapping effect is improved, and the gear lapping precision is improved.
Secondly, (2) assembly of a gear link assembly in a vibration generating mechanism of a gear lapping device
The gear connecting rod assembly of the vibration generating mechanism comprises a lapping gear A4, a connecting rod A6, a connecting rod B7, a dense ball bearing 8, a gear spindle 9, a lapping gear B10, a tension spring 11, a rubber end cover B12, a rubber end cover A13, a connecting bolt B14 and a connecting bolt A15. The wire diameter of the tension spring 11 is 1mm, the effective length is 80mm, and the total length is 128 mm; the fixed end of the connecting rod A6 is provided with a bearing mounting hole which is matched with a bearing in a small interference manner, the interference magnitude is about 3 mu M, the other end of the connecting rod A6 is provided with a threaded through hole M8, the connecting rod A6 is made of bearing steel, the hardness of the material can reach HRC55 after quenching and medium-temperature tempering, and the connecting rod has high wear resistance, and when the connecting rod is contacted with the vibration generator 1, the vibration generator 1 is preferentially worn; a triangular groove is formed in the side face of the connecting rod, one side face of the groove is in contact with the vibration generator, and the side face is subjected to precision grinding processing, so that the surface roughness is below Ra0.4; the link B7 has a structure that has only triangular grooves open to opposite sides as compared to the link A6, and the remaining structural features are the same.
The center of the gear mandrel is provided with a conical countersunk through hole, so that the gear mandrel and the connecting rod can be conveniently installed and positioned for installing the connecting bolt, the length of the connecting bolt is proper, when the gear mandrel is installed in place, one end of the connecting bolt extends out of the end surface of the connecting rod by about 5-10 mm, an annular groove with the diameter of 1.2mm is machined at the extending end of the connecting bolt, the position of the annular groove is as close to the end surface of the connecting rod as possible, hooks at two ends of the tension spring 11 are installed in the annular groove of the connecting bolt, therefore, the influence of overturning torque generated by the tension spring force on the position precision of the connecting rod can be reduced, and after the tension spring 11 is installed, about 5N pretension force is left. The installation end face of the gear mandrel and the connecting rod needs to be precisely ground, the flatness of the end face needs to reach 1 mu m, the dense ball bearing 8 is installed between the gear mandrel and the opposite grinding gear, the unilateral interference magnitude of a spherical rolling body with the precision of above G5 grade and a shaft and a hole selected by the dense ball bearing 8 is 0-3 mu m, the rubber end cover A13 is installed on the end face of one end of the gear, the inner hole of the rubber end cover is tightly attached to the ring surface of the gear, the center of the rubber end cover is provided with a hole with the diameter consistent with that of the gear mandrel, and the hole can be used for penetrating through the gear mandrel to prevent grinding agents from entering a gear rotary shaft system.
Finally, (3) a method for designing a vibration generator in a vibration generating mechanism of a gear lapping device
The oscillation amplitude motion of a gear generated by a vibration generator in a vibration generating mechanism of a gear lapping device is used as the lapping main motion of the lapping gears, the outer contour of the vibration generator is formed by connecting 16 sections of arc surfaces with equal radius smoothly, the central angles of the arc sections are equal and are uniformly distributed on a concentric circle of the rotation center of the vibration generator, and two end points of each arc section are equal to the rotation center of the vibration generator and are l. When the middle vertex of the arc is contacted with the connecting rod, the connecting rod is at the maximum limit position of swinging; when the two connected arcs are tangent to the connecting rod, the connecting rod is at the minimum limit position of swinging. When designing the outer contour shape of the vibration generator, the most important design objective is to determine the maximum value and the minimum value of the swinging of the connecting rod, and the two design objectives are related to the distance l between the two end points of the circular arc and the rotation center of the vibration generator, the radius r of the circular arc and the corresponding central angle; meanwhile, the swinging frequency of the connecting rod can also directly influence the efficiency of the gear lapping pair, the swinging frequency of the connecting rod is in direct proportion to the number of arc segments on the outer contour of the vibration generator and the rotating speed of the connecting rod, and a specific mathematical relationship can be represented by a formula: n, wherein f is the swinging frequency (Hz) of the connecting rod, N is the number of outer contour arc surfaces of the vibration generator, and N is the rotating speed (rps) of the vibration generator; the maximum and minimum values of the link oscillation are expressed by mathematical formulas:
in the formula, LmaxIs the maximum value (mm) of the link oscillation, LminThe minimum value (mm) of the swing of the connecting rod is represented by a, the distance (mm) between the initial position of the connecting rod and the rotation center of the vibration generator is represented by an initial position, the initial position refers to that two gears in standard meshing are in standard meshing, the center distance between the two gears is a standard center distance, namely d is mz, wherein m is the module of the gear to be ground, z is the number of teeth of the gear to be ground, l is the distance (mm) between the two ends of the arc and the rotation center of the vibration generator, r is the radius (mm) of the arc, alpha is the corresponding center angle (degree) of the arc on the vibration generation, the size is one n fraction of 360 degrees, and n is the number of the outer contour arcs of the vibration generator.
From the above calculation formula, the design steps of the vibration generator of the vibration generating mechanism of the gear lapping device are as follows:
when the included angle of the two connecting rods is the maximum value, the vibration generator is contacted with the two connecting rods, and a proper back clearance is still left between the two opposite grinding gears; when the included angle of the two connecting rods is the minimum value, the two opposite grinding gears are meshed without back clearance, and a proper clearance is reserved between the vibration generator and the two connecting rods.
(1) Firstly, determining the length of a common normal line of two opposite-grinding gears measured by a design target, and calculating the variation of the center distance of the opposite-grinding gears brought by the margin of the common normal line; determining the maximum value of the swinging of the connecting rods, wherein the maximum value is required to be about 0.2mm larger than the variation of the center distance of the gears, so that the vibration generator is ensured to be in contact with the two connecting rods, and a proper back clearance is still left between the two opposite grinding gears; secondly, after the gears are subjected to opposite grinding, the length of a common normal line of the gears is reduced, the target length of the common normal line of the gears after opposite grinding is determined, then the variation of the center distance of the gears after opposite grinding is calculated according to the allowance of the common normal line, and finally the minimum value of the swinging of the connecting rods is determined, wherein the value is required to be about 0.1mm smaller than the variation of the center distance of the gears after opposite grinding, so that the two opposite grinding gears are enabled to be meshed without backlash, and a proper gap is formed between the vibration generator and the contact of the two connecting rods.
(2) The frequency of the vibration of the connecting rod is determined, the higher the vibration frequency of the connecting rod is, the higher the grinding efficiency of the gear pair is, but the high frequency is not beneficial to improving the grinding precision of the gear due to the restriction of dynamic factors. In this patent, the vibration frequency of the connecting rod is selected to be 8Hz, the rotating speed N of the vibration generator is selected to be 0.5rps, then a formula is substituted, the number of arc segments N of the outer contour of the vibration generator is calculated to be 16, 16 arc surfaces are smoothly connected to form a complete closed contour, and the central angle α corresponding to each arc segment is 22.5 °.
(3) Deriving L from the parameters determined abovemax、LminAnd alpha, substituting the values into a formula to calculate the values of l and r, and designing the vibration generator according to the two values.
Opposite grinding method for vibration generating mechanism of gear opposite grinding device
The two counter-grinding gears are arranged at the appointed positions of the gear counter-grinding device, grinding agents are uniformly coated on each gear tooth of the two counter-grinding gears, a meshing transmission motor of the counter-grinding gears is started firstly, then a driving motor of a vibration generating mechanism is started, a vibration generator is made to rotate at a constant speed, the rotating speed is about 0.5rps, the vibration generator drives two connecting rods and the counter-grinding gears to swing in a reciprocating mode according to fixed frequency, the frequency is about 8Hz, the two counter-grinding gears are driven to do continuous meshing transmission in the reciprocating swing process, under the driving of the two motions, the tooth surfaces of the two counter-grinding gears rub and impact in a reciprocating mode, and materials in the relatively high point areas of the tooth surfaces are removed in a micro mode under the action of the grinding agents. With the continuous grinding, the deviation of the tooth profile and the spiral line of the gear is reduced, the scratching action between the tooth surfaces is weakened, and the grinding is stopped after the expected processing effect is achieved.
Claims (7)
1. A vibration generating mechanism for a gear lapping device is characterized by comprising a vibration generator (1), a flange shaft (2), a coupler (3), a lapping gear A (4), a motor (5), a connecting rod A (6), a connecting rod B (7), a dense ball bearing (8), a gear mandrel (9), a lapping gear B (10), a spring (11), a rubber end cover A (12), a rubber end cover B (13), a connecting bolt A (14) and a connecting bolt B (15);
the outer contour of the vibration generator (1) is formed by smoothly connecting arc surfaces with equal radiuses, a circular hole is formed in the center of the vibration generator and is installed on a flange shaft (2), the flange shaft (2) is connected with a motor (5) through a coupler (3), and the motor (5) rotates to drive the flange shaft (2) and the vibration generator (1) to synchronously rotate; triangular openings are formed in two opposite side faces of a connecting rod A (6) and a connecting rod B (7), a vibration generator (1) is arranged between the two openings, the top ends of the connecting rod A (6) and the connecting rod B (7) are fixed, gear mandrels (9) are installed at the tail ends of the two connecting rods and are respectively fixed by a connecting bolt A (14) and a connecting bolt B (15), dense ball bearings (8) are installed in central holes of two oppositely ground gears and then are installed on the gear mandrels (9) together; the lengths of the connecting bolt A (14) and the connecting bolt B (15) are higher than the thicknesses of the connecting rod A (6) and the connecting rod B (7), the tail end of the connecting bolt A and the connecting bolt B is provided with a ring groove with the diameter larger than the diameter of the tension spring, and the two ends of the tension spring are connected in a hooking way; the two hooks are sleeved on the connecting bolt, and under the action of the tension spring, the lower side edges of the triangular openings of the two connecting rods are ensured to be in contact with the arc surface of the vibration generator or be meshed with the two counter-grinding gears without back clearance when being driven by the vibration generator; under the rotation drive of the vibration generator, the two connecting rods synchronously swing along two symmetrical directions, the tooth surfaces of the two counter grinding gears are subjected to reciprocating scratching and impacting, and materials in the relatively high point areas of the tooth surfaces are slightly removed under the action of grinding agents.
2. The vibration generating mechanism for a gear lapping device according to claim 1, wherein the number of the circular arc surfaces with the same radius of the outer contour of the vibration generator is even, and the larger the number of the circular arc surfaces is, the higher the vibration frequency of the lapping gear under the same rotation speed is.
3. A vibration generating mechanism for a gear lapping device according to claim 1 or 2, wherein when the angle between the two connecting rods is at a minimum, the two lapping gears are in backlash free engagement, and there is a suitable clearance between the vibration generator and the contact of the two connecting rods; when the included angle of the two connecting rods is the maximum value, the vibration generator is contacted with the two connecting rods, and a proper back clearance is still left between the two oppositely grinding gears.
4. A vibration generating mechanism for a gear lapping device according to claim 1 or 2, wherein the side of the triangular gap of the connecting rod a (6) and the connecting rod B (7) contacting the vibration generator has a surface roughness below ra0.4.
5. A vibration generating mechanism for a gear lapping device according to claim 1 or 2, wherein the vibration generator is designed using the formula:
in the formula, LmaxIs the maximum value of the swinging of the connecting rod in mm, LminThe distance between the initial position of the connecting rod and the rotation center of the vibration generator is in mm, the initial position refers to that two counter-grinding gears are in standard meshing, the center distance between the two gears is a standard center distance, namely d is mz, wherein m is the module of the gear to be ground, z is the number of teeth of the gear to be ground, l is the distance between the two ends of the circular arc and the rotation center of the vibration generator, r is the radius of the circular arc, mm is the unit, alpha is the corresponding central angle of the circular arc on vibration generation, degree is one n-th of 360 degrees, and n is the number of the circular arcs on the outer contour of the vibration generator.
6. A vibration generating mechanism for a gear lapping device according to claim 1 or 2, wherein the frequency of the vibration generator satisfies the condition:
f＝nN
in the formula, f is the swing frequency of the connecting rod, the unit Hz, N is the number of the outer contour arcs of the vibration generator, and N is the rotating speed of the vibration generator, and the unit rps.
7. A vibration generating mechanism for a gear lapping device according to claim 1, wherein the material of the connecting rod a (6) and connecting rod B (7) is CGr15 bearing steel, after quenching, the hardness is not lower than HRC 50; the material of the vibration generator is a material having friction reducing properties to reduce wear of the vibration generator and the connecting rod.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114178631A (en) * | 2021-12-09 | 2022-03-15 | 中国船舶重工集团公司第七0三研究所 | Pneumatic type spiral spline grinder |
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