CN115091150A - Rapid trial-manufacturing method of high-precision transmission gear and transmission gear - Google Patents

Rapid trial-manufacturing method of high-precision transmission gear and transmission gear Download PDF

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Publication number
CN115091150A
CN115091150A CN202210726114.9A CN202210726114A CN115091150A CN 115091150 A CN115091150 A CN 115091150A CN 202210726114 A CN202210726114 A CN 202210726114A CN 115091150 A CN115091150 A CN 115091150A
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gear
bar
face
transmission gear
precision
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CN115091150B (en
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张瑜
刘井泽
王乐
周仁杰
王健夫
仉天玺
霍星宇
马旭东
李敬超
张人搏
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FAW Group Corp
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FAW Group Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels

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Abstract

The technical scheme of the invention provides a rapid trial-manufacturing method of a high-precision transmission gear and the transmission gear manufactured by the method, wherein a soft jaw chuck is used for clamping a gear bar to perform rough machining and finish machining during machining to obtain a gear blank, and the matched soft jaw chuck machining mode, soft jaw chuck clamping position and bar machining surface size are selected according to the size of a workpiece, so that the rapid trial-manufacturing method of the gear suitable for small-batch gear production is provided, and the gear manufactured by the method can meet the high-precision requirement of the automobile transmission gear.

Description

Rapid trial-manufacturing method of high-precision transmission gear and transmission gear
Technical Field
The invention belongs to the field of transmission gear machining, and particularly relates to a rapid trial-manufacturing machining method of a high-precision transmission gear and a transmission gear manufactured by the machining method.
Background
With the improvement of living standard, the automobile industry tends to widen vehicle functions and pursues diversification of use scenes, which puts new requirements on the automobile gearbox, and the gear serving as one of important transmission mechanisms of the gearbox is required to have structural size precision and material strength enough to bear complex working conditions such as high rotating speed, high load and the like. For example, the requirement of the double-clutch transmission with a complex structure on the positioning reference precision of the inner hole of the gear is within 0.015mm, so that the running abrasion of the gear is reduced, the service lives of the gear and a gearbox are prolonged, and the noise and vibration of the whole vehicle are reduced.
The existing transmission gear is generally processed by adopting special equipment and a special clamp, has high processing cost and long production period, is not suitable for small-batch processing production, and lacks a rapid trial-manufacturing processing method which can ensure the processing precision of the transmission gear and is suitable for small-batch gear production.
Disclosure of Invention
In order to overcome the defects in the background art, the technical scheme of the invention provides a rapid trial-manufacturing processing method of a high-precision transmission gear, which comprises the following steps:
s1, clamping a gear bar by using a soft jaw chuck to perform rough machining and finish machining to obtain a gear blank;
s2, hobbing;
s3, heat treatment;
s4, grinding;
s5, performing finish machining on the surface of the semi-finished gear after heat treatment by using a forming gear grinding machine to obtain a transmission gear with precision of more than six grades;
wherein, the rough machining in the step S1 includes the following steps:
s11, the gear bar enters the soft jaw chuck in a first preset length and clamps the excircle of the bar by the soft jaw chuck, and the first end face of the bar protrudes towards the outer side of the chuck;
s12, turning the gear inner hole, the first end face of the gear bar and the outer circle of the bar, wherein the processing surface of the outer circle of the bar extends for a second preset length from the first end face of the bar to the second end face of the bar, and the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar;
the finishing in step S1, including the steps of:
s13, machining the inner side of the soft jaw chuck to enable the soft jaw chuck to stably clamp the outer circle diameter of the workpiece turned by the S12 in an arc shape;
and S14, face adjusting, clamping and inserting the gear bar, inserting the gear bar into the soft jaw chuck by a third preset length, turning the second end face, and controlling the second preset length to be larger than the third preset length.
Further, in step S12, the coaxiality of the first end face and the inner hole is controlled to be less than or equal to 0.01 mm.
Further, in step S14, the runout of the soft jaw chuck is controlled to be less than or equal to 0.01mm, and the perpendicularity between the inner hole of the chuck and the end surface of the chuck is controlled to be less than or equal to 0.005 mm.
Further, step S4 is executed, the heat-treated tooth blank is positioned and processed by the inner bore and the end face of the inner bore by using the inner and outer cone combined grinder, the roundness of the inner bore of the treated tooth blank is controlled within 0.005, the cylindricity is controlled within 0.01, the verticality between the second end face and the inner bore is controlled within 0.005, and the gear precision is controlled to be more than six levels.
Further, in steps S12 and S14, the transmission gear workpiece roughness is controlled not to be greater than ra 1.6.
Further, before the step S5 is executed, the precision of the jig is adjusted to be within 0.003mm, and after the inner hole is expanded by the expansion sleeve, the center is used to push the expansion sleeve tightly, and the second end face is used as a positioning face to perform gear grinding.
Further, step S5 includes the steps of:
s51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feed ratio of the dressing wheel during each rotation of the grinding wheel;
and S52, performing rough grinding and finish grinding treatment on the surface of the semi-finished gear by using the dressed grinding wheel.
Further, in performing the rough grinding process, the line speed ratio is configured to be 0.8, and the feed amount ratio is configured to be 6; when the refining process is performed, the line speed ratio is set to-0.8 and the feed ratio is set to 10.
Further, in step S5, the tooth form inclination deviation is controlled to be within 5 steps, the tooth direction helix angle deviation is controlled to be within 6 steps, the pitch cumulative deviation does not exceed 4 steps, and the tooth form drum amount is less than 0.008 mm.
The invention also provides a high-precision transmission gear which is manufactured by adopting the rapid trial-manufacturing processing method of the high-precision transmission gear.
The technical scheme of the invention provides a rapid trial-manufacturing method of a high-precision transmission gear and the transmission gear manufactured by the method, wherein a soft jaw chuck is used for clamping a gear bar to perform rough machining and finish machining during machining to obtain a gear blank, and the matched soft jaw chuck machining mode, soft jaw chuck clamping position and bar machining surface size are selected according to the size of a workpiece, so that the rapid trial-manufacturing method of the gear suitable for small-batch gear production is provided, and the gear manufactured by the method can meet the high-precision requirement of the automobile transmission gear.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below.
FIG. 1 is a schematic flow diagram of a rapid trial manufacturing process for a high precision transmission gear;
FIG. 2 is a schematic view of a machining structure for clamping gear bars by using a soft jaw chuck;
FIG. 3 is a second schematic view of a processing structure for clamping gear bars by using a soft jaw chuck;
fig. 4 is a schematic view of a gear machining structure for gear grinding by using a tip to push an expansion sleeve tightly.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Before discussing exemplary embodiments in more detail, it should be noted that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel, concurrently, or simultaneously. In addition, the order of the operations may be re-arranged. A process may be terminated when its operations are completed, but may have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc.
Specific structural and functional details disclosed herein are merely representative and are provided for purposes of describing example embodiments of the present invention. This invention may, however, be embodied in many alternate forms and should not be construed as limited to only the embodiments set forth herein.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
With the improvement of living standard, the automobile industry tends to broaden vehicle functions and pursue diversification of use scenes, consumers expect that the automobile not only has the shock resistance of a cross-country vehicle, but also has the mute comfort of a car, so that new requirements are put forward on an automobile gearbox, particularly, the requirements on the bearing capacity, the shock resistance, the noise performance and the like of a gear which is one of important transmission mechanisms of the gearbox are higher and higher, and the requirements on the structural size precision and the material strength of the gear are enough to bear complex working conditions such as high rotating speed, high load and the like.
For example, a gear box of a double-clutch transmission with a complex structure comprises a plurality of gears and an input shaft, and the requirement on the assembly precision is high, so that the requirement on the positioning reference precision of an inner hole is within 0.015mm, because the long-time high-speed and strong-load operation directly influences the service life of the transmission, the higher the gear precision is, the smoother the gear precision is when the gear precision is meshed with other gears, the reduction of the gear impact is facilitated, the running abrasion of the gears is reduced, the service lives of the gears and the transmission are further prolonged, and the noise and vibration of the whole vehicle are reduced.
The existing transmission gear is generally processed by adopting special equipment and special clamps, has high processing cost and long production period, is not suitable for small-batch processing production, and lacks a rapid trial-manufacturing processing method which can ensure the processing precision of the transmission gear and is suitable for small-batch production of the gear at present.
In order to overcome the defects, the technical scheme of the invention provides a rapid trial-manufacturing method of a high-precision transmission gear and the transmission gear manufactured by the method, when in processing, a soft-jaw chuck is used for clamping a gear bar to perform rough machining and finish machining to obtain a gear blank, and the soft-jaw chuck processing mode, the soft-jaw chuck clamping position and the bar processing surface size matched with the gear blank are selected according to the workpiece size, so that the gear rapid trial-manufacturing method suitable for small-batch gear production is provided, and the gear manufactured by the method can meet the high-precision requirement of the automobile transmission gear.
The technical solution of the present invention will be further described in detail with reference to the accompanying drawings 1-4 and the specific embodiments.
The first embodiment of the invention:
the technical scheme of the invention provides a rapid trial-manufacturing processing method of a high-precision transmission gear, the processing method and the structure are shown in figures 1-4, and the method comprises the following steps:
and step S1, clamping the gear 2 bar by using the soft jaw chuck 1 to perform rough machining and finish machining to obtain a gear blank, wherein the gear 2 bar can be flexibly selected, special equipment and furniture do not need to be customized according to the size of the bar, and the gear blank machining method is beneficial to improving the production efficiency, shortening the production period and reducing the production cost.
Specifically, the rough machining in step S1 includes the steps of:
s11, the gear 2 bar enters the soft jaw chuck by a first preset length and clamps the excircle of the bar by the soft jaw chuck, and the first end face 3 of the bar protrudes to the outer side of the chuck.
Introducing a soft jaw chuck and clamping the excircle of the gear bar to be processed by using the soft jaw chuck, wherein one end part of the gear bar penetrates into the soft jaw chuck by a first preset length and is stably clamped by the soft jaw chuck, the end face of the end part is defined as a second end face, the end face of the other end part is defined as a first end face, and the first end face protrudes outwards relative to the chuck to wait for a subsequent processing procedure.
S12, turning the gear inner hole 4, the first end face 3 of the gear bar and the outer circle of the bar, wherein the machined surface of the outer circle of the bar extends for a second preset length from the first end face 3 of the bar to the second end face 5 of the bar, and the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar.
The gear bar is fixed by using a soft jaw chuck, all elements of a gear inner hole 4 and a first end face 3 of the gear bar and a bar outer circle structure are machined by turning, wherein the length of a gear machining face of the bar outer circle structure is preset, the machining face of the bar outer circle extends from the first end face 3 of the bar to a second end face 5 by a second preset length, the sum of the first preset length and the second preset length is controlled to be smaller than the bar width, a turning space enough for roughly machining the first end face is reserved, interference with the soft jaw chuck is avoided when the second end face is machined by adjusting the face, and the gear machining precision is controlled to meet the precision requirement of a vehicle transmission gear.
Optionally, step S12 is executed, and the workpiece roughness of the transmission gear is not greater than ra1.6, so as to ensure that the machining precision of the gear blank meets the precision requirement of the automobile transmission gear when the soft jaw chuck is used for machining the first end face of the bar stock at S12, and provide the high-precision gear blank as the subsequent machining basis.
Step S1 is that after the rough machining step, the face-adjusting transmission gear blank is clamped by the soft jaw chuck 1 and a finish machining process is performed on the second end face of the gear blank, the finish machining process includes the following steps:
and S13, machining the inner side of the soft jaw chuck 1 to enable the soft jaw chuck to stably clamp the outer circle of the workpiece turned by the S12 in an arc shape.
And according to the excircle diameter of the gear blank workpiece, turning the inner side of the soft jaw chuck to be machined into an arc matched with the excircle diameter of the gear blank workpiece, stably clamping the excircle of the workpiece subjected to S12 turning by the soft jaw chuck, and waiting for a subsequent machining process.
And S14, face adjusting, clamping and inserting the gear bar, inserting the gear bar into the soft jaw chuck by a third preset length, turning the second end face 5, and controlling the second preset length to be larger than the third preset length.
And adjusting the surface to clamp the gear bar, wherein a second end surface 5 of the bar protrudes outwards relative to the soft jaw chuck 1, and turning is performed on the second end surface, in the process, the gear bar is kept to penetrate into the turned soft jaw chuck by a third preset length and is stably clamped with an excircle by the soft jaw chuck, and the third preset length is controlled to be smaller than the second preset length so as to avoid interference of the soft jaw chuck during turning of the gear, so that the machining precision of the gear is controlled to meet the precision requirement of the gear of the vehicle transmission.
Optionally, step S14 is executed to control the workpiece roughness of the transmission gear not to be larger than ra1.6, so as to ensure that the machining precision of the gear blank meets the precision requirement of the automobile transmission gear when the soft jaw chuck is used for machining the first end face of the bar stock at S12, and provide the high-precision gear blank as the subsequent machining basis.
Optionally, in step S14, the runout of the soft jaw chuck is controlled to be less than or equal to 0.01mm, and the perpendicularity between the inner hole of the chuck and the end face of the chuck is controlled to be less than or equal to 0.005mm, so as to ensure that the tooth blank precision obtained by clamping and turning the tooth blank by using the improved soft jaw chuck in S14 meets the requirements of the gear of the automotive transmission.
And step S2, hobbing the gear tooth surface by using a hobbing machine.
Optionally, in step S2, the coaxiality between the first end surface of the gear blank and the inner hole of the gear blank is controlled to be less than or equal to 0.01mm, so as to ensure that the gear machining precision meets the precision requirement of the gear of the automobile transmission, and to avoid poor meshing and gear impact during the gear operation.
And step S3, heat treatment.
Optionally, in consideration of the fact that the transmission gear requires high strength to withstand high load operating conditions, the gear is subjected to heat treatment by quenching.
And step S4, grinding.
Optionally, in step S4, the internal and external cone combined grinding machine is used to position and process the heat-treated tooth blank with the end surfaces of the internal hole and the internal hole, the roundness of the internal hole of the processed tooth blank is controlled within 0.005, the cylindricity is controlled within 0.01, the verticality of the second end surface and the internal hole is controlled within 0.005, and the precision of the gear after grinding can reach more than six grades, so as to ensure that the gear meets the precision requirement of the gear processing of the automobile transmission.
And step S5, processing the surface of the semi-finished gear after heat treatment by using a forming gear grinding machine to obtain the transmission gear with the precision of more than six grades. And (3) processing the surface of the semi-finished gear after heat treatment by adopting a forming gear grinding machine, wherein gear grinding is used as the last process for processing the hard tooth surface of the gear to correct the error before gear grinding and obtain high gear precision.
Optionally, before the gear grinding machine is used for machining, the dressing wheel is controlled to dress the shape of the grinding wheel, so that a certain distortion amount is generated in the grinding process to reduce the natural distortion amount of the gear, and the machining precision of the gear is improved.
Specifically, step S5 includes the steps of:
and S51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feed ratio of the dressing wheel during each rotation of the grinding wheel.
And S52, performing rough grinding and finish grinding treatment on the surface of the semi-finished gear by using the dressed grinding wheel.
When the linear velocity directions of the dressing wheel and the grinding wheel are the same, the distance between the protruded high point (wave crest) and the recessed low point (wave trough) on the surface of the grinding wheel is the largest after the grinding wheel is dressed, the surface of the grinding wheel is sharper, the grinding efficiency is high, and the dressing wheel is suitable for rough grinding. Alternatively, when the rough grinding process is performed, the linear velocity ratio is set to 0.8 to improve the gear rough grinding process efficiency and shorten the rough grinding process time.
When the linear velocity directions of the dressing wheel and the grinding wheel are opposite, the distance between a protruded high point (wave crest) and a recessed low point (wave trough) on the surface of the grinding wheel after the grinding wheel is dressed is small, which indicates that the surface of the grinding wheel is smoother and more parallel, is beneficial to improving the roughness of the tooth surface when a workpiece is ground, but has low grinding efficiency and is suitable for fine grinding. Optionally, when performing the finish grinding process, the line speed ratio is configured to be-0.8 to improve the finish grinding processing effect of the gear and ensure that the precision meets the precision requirement of the transmission gear.
In addition, the dressing degree of the dressing wheel can be controlled by controlling the feed ratio of the dressing wheel per rotation of the grinding wheel to match the requirements of the gear grinding process, and optionally, when the gear grinding machine is used for performing the rough grinding treatment, the feed ratio of the dressing wheel per rotation of the grinding wheel is configured to be 6; in performing the finish grinding process, the feed ratio of the dresser wheel per one rotation of the grinding wheel is set to 10.
Optionally, to improve the precision of gear grinding, before step S5, the precision of the fixture is adjusted to be within 0.003mm, and after the inner hole is expanded by the expansion sleeve 6, the center 7 is used to push the expansion sleeve to perform gear grinding with the second end face as a locating face.
Optionally, in step S5, the tooth form inclination deviation is controlled within 5 steps, the tooth direction helix angle deviation is controlled within 6 steps, the cumulative deviation of the circumferential pitch does not exceed 4 steps, and the tooth form drum amount is less than 0.008mm, so as to ensure that the gear processed by S5 meets the precision requirement of the transmission gear.
The second embodiment of the invention:
on the basis of the first embodiment, the embodiment provides a method for clamping a gear bar by using a soft jaw chuck to perform rough machining and finish machining to obtain a gear blank, which comprises the following steps:
a cylindrical steel material with the length of 40mm and the diameter of 90mm is customized, the outer circle of the bar is clamped by using a soft-jaw chuck, the gear bar penetrates into the soft-jaw chuck to be clamped by 10mm, and the first end face of the bar protrudes towards the outer side of the chuck.
The inner hole of the gear, the first end face of the gear bar and the outer circle of the bar are machined in a turning mode, the machining surface of the outer circle of the bar is 29mm from the first end face of the bar to the second end face of the bar, the coaxiality of the first end face and the inner hole is not larger than 0.01mm, the surface roughness is not larger than Ra1.6, and the diameter of the inner hole is 43 mm.
The inner side of the soft jaw chuck is processed to be arc-shaped, the diameter of an inner hole of the soft jaw chuck is ensured to be 85mm, stable clamping can be formed on a gear bar, the jumping of the soft jaw chuck is controlled not to be more than 0.01mm, the roughness is not more than Ra1.6, and the verticality of the inner hole of the chuck and the end face of the chuck is not more than 0.005 mm.
And (4) adjusting the surface of the gear bar, clamping the gear bar, enabling the gear bar to penetrate into the soft jaw chuck by 18mm, enabling the second end surface to protrude relative to the soft jaw chuck, and turning the second end surface.
The third embodiment of the invention:
the embodiment of the invention provides a high-precision transmission gear, which is manufactured by adopting a rapid trial manufacturing and processing method of the high-precision transmission gear, wherein the rapid trial manufacturing and processing method of the high-precision transmission gear, the processing method and the structure are shown as figures 1-4, and the method comprises the following steps:
and step S1, clamping the gear 2 bar by using the soft jaw chuck 1 to perform rough machining and finish machining to obtain a gear blank, wherein the gear 2 bar can be flexibly selected, special equipment and furniture do not need to be customized according to the size of the bar, and the gear blank machining method is beneficial to improving the production efficiency, shortening the production period and reducing the production cost.
Specifically, the rough machining in step S1 includes the steps of:
s11, the gear 2 bar enters the soft jaw chuck by a first preset length and clamps the excircle of the bar by the soft jaw chuck, and the first end face 3 of the bar protrudes to the outer side of the chuck.
Introducing a soft jaw chuck and clamping the excircle of the gear bar to be processed by using the soft jaw chuck, wherein one end part of the gear bar penetrates into the soft jaw chuck by a first preset length and is stably clamped by the soft jaw chuck, the end face of the end part is defined as a second end face, the end face of the other end part is defined as a first end face, and the first end face protrudes outwards relative to the chuck to wait for a subsequent processing procedure.
S12, turning the gear inner hole 4, the gear bar first end face 3 and the bar outer circle, extending the machined surface of the bar outer circle from the bar first end face 3 to the second end face 5 by a second preset length, and controlling the sum of the first preset length and the second preset length to be smaller than the bar width.
The gear bar is fixed by using the soft claw chuck, a gear inner hole 4 is machined by turning, all elements of a first end face 3 of the gear bar and a bar excircle structure are machined, wherein the length of a gear machining face of the bar excircle structure is preset, the machining face of the bar excircle extends a second preset length from the first end face 3 of the bar to a second end face 5, the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar, a turning space enough for rough machining of the first end face is reserved, and interference with the soft claw chuck is avoided when the second end face is machined by adjusting the face, so that the machining precision of the gear is controlled to meet the precision requirement of a gear of a vehicle transmission.
Optionally, step S12 is executed, and the workpiece roughness of the transmission gear is not greater than ra1.6, so as to ensure that the machining precision of the gear blank meets the precision requirement of the automobile transmission gear when the soft jaw chuck is used for machining the first end face of the bar stock at S12, and provide the high-precision gear blank as the subsequent machining basis.
Step S1 is that after the rough machining step, the face-adjusting transmission gear blank is clamped by the soft jaw chuck 1 and a finish machining process is performed on the second end face of the gear blank, the finish machining process includes the following steps:
and S13, machining the inner side of the soft jaw chuck 1 to enable the soft jaw chuck to stably clamp the outer circle of the workpiece turned by the S12 in an arc shape.
And according to the excircle diameter of the gear blank workpiece, turning the inner side of the soft jaw chuck to be machined into an arc matched with the excircle diameter of the gear blank workpiece, stably clamping the excircle of the workpiece subjected to S12 turning by the soft jaw chuck, and waiting for a subsequent machining process.
And S14, adjusting the surface, clamping the gear bar, enabling the gear bar to penetrate into the soft jaw chuck by a third preset length, turning the second end face 5, and controlling the second preset length to be larger than the third preset length.
And adjusting the surface to clamp the gear bar, wherein a second end surface 5 of the bar protrudes outwards relative to the soft jaw chuck 1, and turning is performed on the second end surface, in the process, the gear bar is kept to penetrate into the turned soft jaw chuck by a third preset length and is stably clamped with an excircle by the soft jaw chuck, and the third preset length is controlled to be smaller than the second preset length so as to avoid interference of the soft jaw chuck during turning of the gear, so that the machining precision of the gear is controlled to meet the precision requirement of the gear of the vehicle transmission.
Optionally, step S14 is executed to control the workpiece roughness of the transmission gear not to be larger than ra1.6, so as to ensure that the machining precision of the gear blank meets the precision requirement of the automobile transmission gear when the soft jaw chuck is used for machining the first end face of the bar stock at S12, and provide the high-precision gear blank as the subsequent machining basis.
Optionally, in step S14, the run-out of the soft jaw chuck is controlled to be less than or equal to 0.01mm, and the perpendicularity between the inner hole of the chuck and the end face of the chuck is controlled to be less than or equal to 0.005mm, so as to ensure that the accuracy of the tooth blank obtained by clamping and turning the tooth blank by using the improved soft jaw chuck in step S14 meets the requirements of the automobile transmission gear.
And step S2, hobbing the gear tooth surface by using a hobbing machine.
Optionally, in step S2, the coaxiality between the first end surface of the gear blank and the inner hole of the gear blank is controlled to be less than or equal to 0.01mm, so as to ensure that the gear machining precision meets the precision requirement of the automobile transmission gear, and avoid poor meshing and gear impact during gear operation.
And step S3, heat treatment.
Optionally, in consideration of the fact that the transmission gear requires high strength to withstand high load operating conditions, the gear is subjected to heat treatment by quenching.
And step S4, grinding.
Optionally, in step S4, the internal and external cone combined grinding machine is used to position and process the heat-treated tooth blank with the end surfaces of the internal hole and the internal hole, the roundness of the internal hole of the processed tooth blank is controlled within 0.005, the cylindricity is controlled within 0.01, the verticality of the second end surface and the internal hole is controlled within 0.005, and the precision of the gear after grinding can reach more than six grades, so as to ensure that the gear meets the precision requirement of the gear processing of the automobile transmission.
And step S5, processing the surface of the semi-finished gear after heat treatment by using a forming gear grinding machine to obtain the transmission gear with the precision of more than six grades. And (3) processing the surface of the semi-finished gear after heat treatment by adopting a forming gear grinding machine, wherein gear grinding is used as the last process for processing the hard tooth surface of the gear to correct the error before gear grinding and obtain high gear precision.
Optionally, before the gear grinding machine is used for machining, the dressing wheel is controlled to dress the shape of the grinding wheel, so that a certain distortion amount is generated in the grinding process to reduce the natural distortion amount of the gear, and the machining precision of the gear is improved.
Specifically, step S5 includes the steps of:
and S51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feed ratio of the dressing wheel during each rotation of the grinding wheel.
And S52, performing rough grinding and finish grinding treatment on the surface of the semi-finished gear by using the dressed grinding wheel.
When the linear velocity directions of the dressing wheel and the grinding wheel are the same, the distance between the protruded high point (wave crest) and the recessed low point (wave trough) on the surface of the grinding wheel is the largest after the grinding wheel is dressed, the surface of the grinding wheel is sharper, the grinding efficiency is high, and the grinding wheel is suitable for rough grinding. Alternatively, when the rough grinding process is performed, the linear velocity ratio is set to 0.8 to improve the gear rough grinding process efficiency and shorten the rough grinding process time.
When the linear velocity directions of the dressing wheel and the grinding wheel are opposite, the distance between the protruded high point (wave crest) and the recessed low point (wave trough) on the surface of the grinding wheel after the grinding wheel is dressed is small, which indicates that the surface of the grinding wheel is smoother and more parallel, and is beneficial to improving the roughness of the tooth surface when a workpiece is ground, but the grinding efficiency is low, and the dressing wheel is suitable for finish grinding. Optionally, when performing the finish grinding process, the line speed ratio is configured to be-0.8 to improve the finish grinding processing effect of the gear and ensure that the precision meets the precision requirement of the transmission gear.
In addition, the dressing degree of the dressing wheel can be controlled by controlling the feed ratio of the dressing wheel per rotation of the grinding wheel to match the requirements of the gear grinding process, and optionally, when the gear grinding machine is used for performing the rough grinding treatment, the feed ratio of the dressing wheel per rotation of the grinding wheel is configured to be 6; in performing the finish grinding process, the feed ratio of the dresser wheel per one rotation of the grinding wheel is set to 10.
Optionally, to improve the precision of gear grinding, before step S5, the precision of the fixture is adjusted to be within 0.003mm, and after the inner hole is expanded by the expansion sleeve 6, the center 7 is used to push the expansion sleeve to perform gear grinding with the second end face as a locating face.
Optionally, in step S5, the tooth form inclination deviation is controlled within 5 steps, the tooth direction helix angle deviation is controlled within 6 steps, the cumulative deviation of the circumferential pitch does not exceed 4 steps, and the tooth form drum amount is less than 0.008mm, so as to ensure that the gear processed by S5 meets the precision requirement of the transmission gear.
The above detailed description is provided for the rapid trial-manufacturing method of the high-precision transmission gear and the transmission gear, and a specific example is applied in the description to explain the principle and the implementation manner of the invention, and the description of the above embodiment is only used to help understand the core idea of the invention; meanwhile, for a person skilled in the art, according to the idea and method of the present invention, there may be variations in the specific embodiments and the application scope, and in conclusion, the content of the present specification should not be construed as a limitation to the present invention.

Claims (10)

1. A rapid trial-manufacturing processing method of a high-precision transmission gear is characterized by comprising the following steps:
step S1, clamping a gear bar by using a soft jaw chuck to perform rough machining and finish machining to obtain a gear blank;
step S2, gear hobbing;
step S3, heat treatment;
step S4, grinding;
step S5, performing gear grinding processing on the surface of the semi-finished gear after heat treatment by using a forming gear grinding machine to obtain a transmission gear with accuracy of more than six grades;
wherein, the rough machining in the step S1 includes the following steps:
s11, the gear bar enters the soft jaw chuck in a first preset length, the outer circle of the bar is clamped by the soft jaw chuck, and the first end face of the bar protrudes towards the outer side of the chuck;
s12, turning the gear inner hole, the first end face of the gear bar and the outer circle of the bar, wherein the processing surface of the outer circle of the bar extends for a second preset length from the first end face of the bar to the second end face of the bar, and the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar;
the finishing in step S1, including the steps of:
s13, machining the inner side of the soft jaw chuck to enable the soft jaw chuck to stably clamp the outer circle of the workpiece turned by the S12 in an arc shape;
and S14, face-adjusting and clamping the gear bar, wherein the gear bar penetrates into the soft jaw chuck by a third preset length, turning a second end face, and controlling the second preset length to be larger than the third preset length.
2. The rapid trial manufacturing method of a high-precision transmission gear according to claim 1, wherein in the step S12, the coaxiality of the first end surface and the inner hole is controlled to be 0.01mm or less.
3. The rapid trial-manufacturing method of a high-precision transmission gear according to claim 1, wherein in step S14, the run-out of the soft-jaw chuck is controlled to be 0.01mm or less, and the perpendicularity between the inner bore of the chuck and the end face of the chuck is controlled to be 0.005mm or less.
4. The method for rapid trial-manufacturing of a high-precision transmission gear according to claim 1, wherein in step S4, the internal hole and the end face of the internal hole are positioned and processed by using an internal and external cone combined grinder, the roundness of the internal hole of the processed gear blank is controlled to be within 0.005, the cylindricity is controlled to be within 0.01, the verticality between the second end face and the internal hole is controlled to be within 0.005, and the gear precision is controlled to be more than six levels.
5. The rapid trial manufacturing method of a high-precision transmission gear according to claim 1, wherein the steps S12 and S14 are performed to control the roughness of the transmission gear workpiece to be not more than ra 1.6.
6. The method for rapid trial manufacturing of a high-precision transmission gear according to claim 1, wherein before the step S5, the jig is adjusted to a precision within 0.003mm, and after the inner hole is expanded by the expansion sleeve, the second end face is used as a positioning face to perform the gear grinding process by using the center-pressing expansion sleeve.
7. The rapid trial manufacturing method of a high-precision transmission gear according to claim 1, wherein the step S5 includes the steps of:
s51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feed ratio of the dressing wheel when the grinding wheel rotates for one circle;
and S52, performing rough grinding and finish grinding treatment on the surface of the semi-finished gear by using the dressed grinding wheel.
8. The rapid trial manufacturing method of a high-precision transmission gear according to claim 7, wherein, in performing the rough grinding process, the linear velocity ratio is configured to be 0.8, the feed amount ratio is configured to be 6; when the refining process is performed, the line speed ratio is set to-0.8 and the feed ratio is set to 10.
9. The rapid trial manufacturing method of a high-precision transmission gear according to claim 7, wherein in step S5, the tooth form inclination deviation is controlled to be within 5 steps, the tooth direction helix angle deviation is controlled to be within 6 steps, the cumulative pitch deviation does not exceed 4 steps, and the tooth form crown amount is less than 0.008 mm.
10. A high-precision transmission gear characterized by being manufactured by a rapid trial manufacturing method of a high-precision transmission gear according to any one of claims 1 to 9.
CN202210726114.9A 2022-06-23 2022-06-23 Rapid trial-manufacturing processing method of high-precision transmission gear and transmission gear Active CN115091150B (en)

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US4672729A (en) * 1983-10-20 1987-06-16 O-Oka Forge Co. Ltd Method for machining clutch gear for automobile transmission
JP2009034785A (en) * 2007-08-02 2009-02-19 Honda Motor Co Ltd Gear machining method
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