JP2000005932A - Method for shaping gear - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a gear shaping method whereby a gear can be cut at low cost through dry cutting at high speed. SOLUTION: At least one film composed basically of AlOx (1.0<=x<=1.5) is subjected to dry cutting whereby it is cut by a pinion cutter 5 coated at least on its flank, at a cutting speed of 400 m/min or less without use of cutting fluid, to create a tooth profile. High-efficiency dry cutting gear shaping using the pinion cutter 5 that uses high-speed tool steel is achieved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a gear machining method for creating and finishing a tooth profile using a tool made of high-speed tool steel.

[0002]

2. Description of the Related Art In the field of gear processing, creation of tooth profiles
In the case of finishing cutting, etc., from the viewpoint of improving the working environment and shortening the processing time to reduce costs, there is an increasing demand for performing high-speed processing without applying cutting oil to the cutting portion, that is, dry cutting. Is coming. For this reason, various techniques have been used for machining using high-speed tool steel, cemented carbide, or the like as a tool.

[0003]

However, in the case of using a tool based on high-speed tool steel, in order to perform cutting by so-called dry cutting without applying a cutting oil, breakage of the tool is prevented. For this reason, the current situation is that the processing speed must be reduced. In addition, when a tool based on a cemented carbide alloy is used, the tool hardly breaks even when dry cutting is performed, but since the cemented carbide alloy is very expensive, there is a problem in terms of cost and practical use Was difficult. As described above, in the field of gear processing, it has not been possible to perform high-speed processing by dry cutting at low cost.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a gear machining method capable of machining gears at low cost and at high speed by dry cutting.

[0005]

According to a first aspect of the present invention, there is provided a method for forming a tooth profile using a high speed tool steel gear-type shaving tool.
A gear type shaving tool coated with at least one layer having a basic composition of 10 _x (1.0 ≤ x ≤ 1.5) on at least the flank, and performs cutting at a cutting speed of 400 m / min or less without using a cutting oil. It is characterized by creating a tooth profile by dry cutting.

In order to achieve the above object, a machining method of the present invention is directed to a method of finishing a gear wheel surface using a shaving cutter made of a high-speed tool steel, the method comprising: AlO _x (1.0 ≦ x ≦ The method is characterized in that the gear tooth surface is finish-cut by dry cutting in which at least one layer of a film having the basic composition described in 1.5) is coated on at least the tooth surface without using a cutting oil.

In order to achieve the above object, a machining method according to the present invention is directed to a gear machining method for forming a bevel gear using a spiral bevel gear cutter in which a blade member made of high-speed tool steel is attached to a cutter body. AlO _x (1.0
≦ x ≦ 1.5). A tooth profile is created by dry cutting in which cutting is performed without using a cutting oil, using a spiral bevel gear cutter to which a blade material coated with at least one layer having a basic composition of ≦ x ≦ 1.5 is applied.

The cutting is performed by blowing air to the cutting portion or the cutter portion other than the cutting portion.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A gear machining method according to the present invention will be described below with reference to the drawings. The gear machining method according to the embodiment includes a gear machining for creating a gear using a gear shaving tool, a finish machining for finishing a gear tooth surface using a shaving cutter, and a bevel gear using a spiral bevel gear cutter. The gears are processed.

A gear machining method for creating a gear using a gear-type shaving tool (pinion cutter) will be described with reference to FIGS.

Referring to FIGS. 1 and 2, the structure of a gear shaper for implementing the gear machining method of the present invention will be described. FIG. 1 shows a schematic configuration of a cutting portion of a gear shaper for implementing the gear machining method of the present invention, and FIG. 2 shows an external appearance of a shaving cutter.

As shown in FIG. 1, a work 3 is attached to a fixture 2 on a table 1 of a gear shaper, and a pinion cutter 5 is attached to a cutter head 4. The table 1 and the cutter head 4 are relatively rotated by a drive mechanism (not shown), and the cutter head 4 reciprocates up and down.
Further, the cutter head 4 and the table 1 are relatively moved to give a cut, and the outer periphery of the work 3 is shaved off by the blade of the pinion cutter 5 to create a tooth profile. During cutting, dry cutting is performed without supplying cutting fluid. In the dry-cut processing, no cutting oil is used, so that there is no generation of stains and unusual odors on the floor, and no waste oil treatment is required. Therefore, it is suitable for improving the working environment and the global environment.

As the pinion cutter 5, a pinion cutter 5 made of high-speed steel (high-speed steel) coated with an oxide of Al is used. As the Al oxide to be coated on the pinion cutter 5, one coated with a single layer and one coated in a multi-layer coating are used. Al coated on pinion cutter 5
The oxide may be coated on at least the flank 5a (see FIG. 2).

As the pinion cutter 5 is coated with an oxide of Al, the temperature of the Al in the coating film increases due to the cutting heat, and as a result, the Al is oxidized by the air and the surface of the coating film is oxidized with high wear resistance. The film is formed, and the pinion cutter 5 is hardly worn. Further, the oxide film has an effect of preventing oxidation inside the film, and can keep the adhesion of the coating film strong.

An embodiment of a gear machining method using the above-described pinion cutter 5 will be described. As the pinion cutter 5, a pinion cutter 5 made of high-speed steel (SKH51) further coated with a material having a composition of AlO _{x at} a thickness of 1.7 μm is used, and cutting is performed without supplying a cutting oil (dry cutting). In addition, as the coating film, Si, Cr, Mg, Ce, Be, C
The oxide-forming element a and other oxide-forming elements may be contained in a small amount of 10% or less (preferably 2% to 3%).

FIG. 3 shows _x of the material having the composition of AlO _x .
4 shows the relationship between the flank wear and the flank wear, and FIG. 4 shows the relationship between the value of x and the crater wear of the material composed of the AlO _x composition. The pinion cutter 5 in FIG. 3 and FIG.
High-speed steel (SKH51) coated with a material of composition _x with a thickness of 1.7 μm, with a module m of 2.5 and a number of teeth of 5
0, outer diameter 130mm. The work 3 is made of SCM43
5. The number of teeth is 50, the tooth width is 20mm, and the helix angle is 20 degrees. The machining conditions are as follows: radial feed: 7 μm / stroke, circumferential feed: 1 mm / stroke, and the number of processed workpieces 3 is 100. Cutting speed is 20m / min, 50m / min, 100m / m for rough cutting
in, 200m / min, 400m / min, and 100m / min in finish cutting.

As shown in FIG. 3, x at a cutting speed of 400 m / min.
The pinion cutter 5 coated with AlO _x having a composition of 1.0 ≦ x ≦ 1.5 has a practical wear limit (0.2 m).
m), and becomes practical. When the cutting speed decreases,
The pinion cutter 5 coated with AlO _x having a composition of _x in the range of 1.0 ≦ x ≦ 1.5 has reduced flank wear.

Although the practical wear limit of flank wear is 0.2 mm or less, the practical wear limit of crater wear shown in FIG.
It is desirable that it be 1 mm or less. As shown in FIG. 4, the crater wear was measured by a pinion cutter 5 coated with AlO _x having a composition in which the value of x was in the range of 1.0 ≦ x ≦ 1.5.
The cutting speed was 0.04 mm or less at any cutting speed, which was within a range that would not affect the cutter life at about 1/5 of the flank wear.

As described above, the pinion cutter 5 made of a high-speed steel coated with a coating film of AlO _x having a composition of _{x in} the range of 1.0 ≦ x ≦ 1.5 has a cutting speed of 40.
By dry cutting within the range of 0 m / min or less, highly efficient and low-cost gear generation can be realized.

FIG. 5 shows a coating of Al ₂ O ₃ , in which an appropriate value of the film thickness was obtained. The horizontal axis of FIG. 5 shows the total film thickness. In other words, if Al ₂ O ₃ is a single layer, it represents the film thickness, and if it is a multilayer (with 0.05 μm thick TiN interposed), it represents the total thickness of all films. is there. The vertical axis represents the ratio of the flank wear when the flank wear of the pinion cutter 5 in which a single layer of Al ₂ O ₃ is coated at a film thickness of 1.7 μm is set to 1. Coating was performed by changing the thickness of the coating film composed of Al ₂ O ₃ in the range of 0.3 μm to 12 μm, and cutting was performed by dry cutting without supplying a cutting oil.

When a single layer of Al ₂ O ₃ is coated,
The wear amount increases when the film thickness is less than 0.5 μm and when the film thickness is more than 10 μm. When the film thickness is between 0.5 μm and 10 μm, the ratio of the amount of abrasion is less than 1, which is below the practicable limit. When multi-layer coating of Al ₂ O ₃
When the thickness is 0.5 μm to 10 μm, the abrasion is reduced as compared with the case where a single layer of Al ₂ O ₃ is coated. Therefore, the thickness of the coating film having the composition of Al ₂ O ₃ is at 0.5 [mu] m or more 10
μm or less, and may be a single layer or multiple layers.

FIG. 6 shows the amount of wear with respect to the circumferential feed. The circumferential feed was changed from 1 mm / stroke to 7 mm / stroke, and cutting was performed by dry cutting without supplying a cutting fluid. FIG. 6 shows the case where the amount of flank wear is within the practical limit. When the circumferential feed was 1 mm / stroke, the wear was within the practical wear limit at a cutting speed of 360 m / min or less.

FIG. 7 shows the relationship between the material and hardness of the work and the cutting speed within the flank wear that can be practically used. That is, the workpiece 3, a typical variety of carburized and hardened steel gears material (e.g. SCM415, SCM435, SCr420 etc., H _B 120 to H
_B 300), carbon steel (e.g. S45C, etc., H _B 150 ~H _B 300
) And iron (e.g. FCD50 etc., in which dry cutting was examined effective cutting speed range by changing the hardness about H _B 150 ~H _B 300). Fig. 7 shows the cutting speed at which the flank wear is below the practical wear limit. From the figure, it can be seen that in the case of carbon steel, the cutting speed is below 390m / min and the wear is within the practical wear limit. It can be seen that the dry cut is effective at 400 m / min or less.

FIG. 8 shows the relationship between the material of the pinion cutter 5 and the cutting speed that can be accommodated in practically available flank wear. That is, for example, as the material of the pinion cutter 5, SKH5
1, SKH55, powdered high speed (1.3% C, 6% W, 5% Mo, others), powdered high speed (2.2% C, 12% W, 2.5% Mo, others), dry cut for various materials Indicates the effective cutting speed range. FIG. 8 shows the cutting speed at which the flank wear is below the practical limit.
At 400 m / min or less, the wear is below the practical wear limit, indicating that dry cutting is effective.

FIG. 9 shows the relationship between the module of the pinion cutter 5 and the cutting speed that can be accommodated in practically available flank wear. That is, FIG. 9 shows a cutting speed range in which dry cutting by changing to the modules 1 to 8 of the pinion cutter 5 is effective. FIG. 9 shows the cutting speed at which the flank wear is less than the practical wear limit, and the cutting speed is 400 m / min regardless of the pinion cutter 5 module.
Below, it can be seen that the wear is below the practical wear limit and dry cut is effective.

As described above, the pinion cutter 5 has Al
At least one layer of a film having a composition of O _x (1.0 ≦ x ≦ 1.5) is coated on at least the flank, and a cutting speed of 40
By creating a tooth profile by dry cutting, which does not use a cutting oil at 0 m / min or less, it is possible to significantly increase the cutting speed without using expensive tools such as cemented carbide and create a tooth profile. it can.

In the above-described gear machining method using the pinion cutter 5, it is also possible to carry out the cutting while blowing air to the cutting portion or a portion other than the cutting portion of the cutter. By performing cutting by the pinion cutter 5 while blowing air, chips generated by the cutting can be blown off and removed, and biting of chips can be prevented. It is also possible to mix a small amount of cutting oil into the air and spray it in a mist. By performing the processing of the gear by blowing air, it is possible to realize the creation of the tooth profile at high efficiency and at low cost without causing the chip to be caught.

Although the pinion cutter 5 has been described as an example of the gear type shaving tool, the present invention can be similarly applied to a rack cutter.

A gear machining method for finish-cutting a gear using a shaving cutter will be described with reference to FIGS.

Referring to FIGS. 10 and 11, the structure of a shaving cutter for carrying out the gear machining method of the present invention will be described. FIG. 10 shows a front view of a shaving cutter for implementing the gear machining method of the present invention, and FIG. 11 shows a state of a main part of the shaving cutter.

As shown in the figure, the shaving cutter 11
A plurality of serrations 14 are formed on a tooth surface 13 of the tooth portion 12, and a cutting edge 15 is formed on the tooth surface 13. A work (not shown) and the shaving cutter 11 are engaged with each other at an axis crossing angle, and one side (shaving cutter 11) is engaged.
Is driven and rotated to rotate the work, so that the cutting blade 15 finely cuts the tooth surface of the work to perform finish cutting. During cutting, dry cutting is performed without supplying cutting fluid. In the dry-cut processing, no cutting oil is used, so that there is no generation of stains and unusual odors on the floor, and no waste oil treatment is required. Therefore, it is suitable for improving the working environment and the global environment.

As the shaving cutter 11, a high-speed steel (high-speed) shaving cutter 11 coated with an oxide of Al is used. Shaving cutter 1
The oxides of Al to be coated on a single layer include those coated with a single layer and those coated with one or more layers in a multilayer coating. Shaving cutter 11
The oxide of Al to be coated on the surface may be coated on at least the tooth surface.

By coating the shaving cutter 11 with an oxide of Al, the temperature of the Al in the coating film is increased by the cutting heat, and as a result, the oxide film is oxidized by the atmosphere and the oxide film having high wear resistance is formed on the surface of the coating film. Are formed, and the shaving cutter 11 is less likely to be worn. Further, the oxide film has an effect of preventing oxidation inside the film, and can keep the adhesion of the coating film strong.

An embodiment of a gear machining method using the above-described shaving cutter 11 will be described. As the shaving cutter 11, 1.7 μm of a material having a composition of AlO _x was used.
Cutting is performed using a high-speed steel (SKH51) shaving cutter 11 which is further coated with m 2 without supplying a cutting oil (dry cutting). The coating film may contain an oxide-forming element of Si, Cr, Mg, Ce, Be, Ca or another oxide-forming element in a small amount of 10% or less (preferably 2% to 3%). .

FIG. 12 shows the relationship between the value of x and the surface roughness of a material composed of AlO _x . Shaving cutter 11 in FIG. 12, high-speed steel (SKH51) further coated with a material having a composition of AlO _x at 1.7 μm
The module m is 2.75, the number of teeth is 73, the outer diameter is 200 mm, and the intersection angle is 15 degrees. It is. The workpiece is made of SCr4
20, the number of teeth is 37, the tooth width is 13mm, and the helix angle is 20 degrees. The cutting conditions are a rotation speed of 200 rpm, a cutting method of plunge processing, and a cut number of 100.

In FIG. 12, the surface roughness (μm) is the worst value (μm R _max ) of all the plunge-shaved workpieces. As shown in FIG. 12, the surface roughness of the shaving cutter 11 coated with AlO _x having a composition of x ≦ 1.0 ≦ x ≦ 1.5 is about 3 μm, which is within the practical range. When the value of x is less than 1.0 and becomes 0.5, the surface roughness exceeds 20 μm and falls outside the practical range. As described above, a high-speed steel shaving cutter 11 coated with a coating film of AlO _x having a composition of x ≦ 1.0 ≦ x ≦ 1.5 can obtain a practically usable surface roughness by dry cutting. Finish cutting can be realized.

FIG. 13 shows an Al ₂ O ₃ coating in which an appropriate value of the film thickness was obtained. The horizontal axis in FIG. 13 represents the total film thickness of Al ₂ O ₃ . In other words, if Al ₂ O ₃ is a single layer, it represents the film thickness, and if it is a multilayer (with 0.05 μm thick TiN interposed), it represents the total thickness of all films. is there. The vertical axis represents the surface roughness (μm R _max ). The thickness of the coating film composed of Al ₂ O ₃ is 0.3
Coating was performed in a range of μm to 12 μm, and cutting was performed by dry cutting without supplying a cutting fluid.

When a single layer of Al ₂ O ₃ is coated,
The surface roughness (μm R _max ) after processing deteriorates when the film thickness is less than 0.5 μm and when the film thickness is more than 10 μm. The film thickness is 0.
When it is 5 μm to 10 μm, the surface roughness (μm R _max ) is 4 μm
Is about R _max, it is understood that the flank wear and crater wear are within the practical range. In the case of multi-layer coating of Al ₂ O ₃ , almost the same results as in the case of single-layer coating were obtained. Therefore, the thickness of the coating film composed of the composition of Al ₂ O ₃ is preferably 0.5 μm or more and 10 μm or less, and may be a single layer or a multilayer.

FIG. 14 shows the relationship between the material and hardness of the work and the surface roughness (μm R _max ). That is, as a work, various typical carburized and case-hardened steel of gear material (for example,
SCM415, SCM435, SCr420 _{etc., H B 120 ~H B 250)} , instead of carbon steel (e.g. S45C, etc., H _B 150 ~H _B 250) and cast iron (eg FCD50 like, the hardness about H _B 150 ~H _B 250) The surface roughness (μm R _max ) was examined. FIG.
Therefore, the surface roughness is 3 μm R _{max for} all materials and hardness.
To 7 μm _max , which makes it practically possible irrespective of the work material and proves that dry cutting is effective.

As described above, the shaving cutter 11
By coating at least one layer of a composition of AlO _x (1.0 ≤ x ≤ 1.5) on at least the tooth surface and performing finish cutting of the gear tooth surface by dry cutting in which cutting is performed without using a cutting oil agent, The cutting speed can be greatly improved without using an expensive tool such as a hard alloy, and the finish cutting of the gear tooth surface can be performed.

In the above-described gear machining method using the shaving cutter 11, it is also possible to carry out the cutting while blowing air to the cutting portion or a portion other than the cutting portion of the cutter. Shaving cutter 1 while blowing air
By performing the cutting according to 1, it becomes possible to blow away and remove the chips generated by the cutting, and it is possible to prevent biting of the chips. It is also possible to mix a small amount of cutting oil into the air and spray it in a mist. By finishing the gear by blowing air,
A tooth profile can be created at high efficiency and at low cost without biting of chips.

A method of machining a gear for creating a bevel gear using a spiral bevel gear cutter will be described with reference to FIGS.

The configuration of a spiral bevel gear cutter for implementing the gear machining method of the present invention will be described with reference to FIGS. FIG. 15 shows the overall configuration of a spiral bevel gear grinding machine for implementing the gear machining method of the present invention, and FIG. 16 shows the appearance of an annular milling cutter as a spiral bevel gear cutter.

As shown in FIG. 15, in the spiral bevel gear cutting machine 21, an annular milling cutter 22 as a spiral bevel gear cutter is mounted on a main shaft 24 side of a cutter head 23, and a work 25 is mounted on a work shaft 26 side. Can be The rotation center axes of the main shaft 24 and the work shaft 26 are arranged so as to intersect in plan view. The cutter head 23 is supported so as to revolve around the center axis of the machine.
Is rotatably supported by the cutter head 23. The work shaft 26 rotates in conjunction with the rotation of the main shaft 24 and the revolution of the cutter head 23. As shown in FIG. 16, the annular milling cutter 22 has a blade material 32
Are mounted in a ring shape. The blade member 32 includes an outside blade 33 and an inside blade 34.

When a tooth profile is created on the work 25 using the spiral bevel gear tooth cutting machine 21, the work 2 is placed on the work shaft 26 side.
5 is attached, and the annular milling cutter 22 is attached to the main shaft 24 side. The cutter head 23 revolves and the main shaft 24 is driven and rotated to revolve and rotate the annular milling cutter 22, and the work shaft 26 is rotated to rotate the work 25. The annular milling cutter 22 revolves around the center of the machine together with the virtual crown gear while rotating, and the tooth surface of the virtual crown gear is drawn by the cutting edge (blade material 32) of the annular milling cutter 22. The work 25 is rotated so as to mesh with the tooth surface to create a tooth surface on the work 25. During cutting, dry cutting is performed without supplying cutting fluid. In the dry-cut processing, no cutting oil is used, so that there is no generation of stains and unusual odors on the floor, and no waste oil treatment is required. Therefore, it is suitable for improving the working environment and the global environment.

The blade material 32 of the annular milling cutter 22 is a high-speed steel (high-speed steel) coated with Al oxide.
The blade material 32 made of is used. As the Al oxide to be coated on the blade material 32, one coated with a single layer and one coated in a multilayer coating are used. The coating film may contain an oxide-forming element of Si, Cr, Mg, Ce, Be, Ca or another oxide-forming element in a small amount of 10% or less (preferably 2% to 3%). .

By coating the blade material 32 with an oxide of Al, the temperature of the Al in the coating film increases due to the cutting heat, and as a result, the oxide film is oxidized by the atmosphere to form a highly wear-resistant oxide film on the surface of the coating film. Are formed, and the blade material 32 is hardly worn. Further, the oxide film has an effect of preventing oxidation inside the film, and can keep the adhesion of the coating film strong.

The relationship between the value and the flank wear of x of the material having the composition of AlO _x in FIG. 17, FIG. 18 shows the relationship between the value and the crater wear of x of the material having the composition of AlO _x is there. The blade material 32 of the annular milling cutter 22 in FIGS. 17 and 18 is made of a material having a composition of AlO _x of 1.7.
μm high-speed steel (SKH55), the body 31 is 6 inches, the point width P of the outside blade 33 and the inside blade 34 is 0.06 inches,
The pressure angle S is 10 degrees to 20 degrees, and the direction is rightward. The material of the work 25 is SCM435. The cutting speed is 40 m / min, 120 m / min, 250 m / min, 500 m / min, and the number of cuts is 300.

As shown in FIG. 17, at a cutting speed of 500 m / min, the blade material 32 coated with AlO _x having a composition of _x in the range of 1.0 ≦ x ≦ 1.5 has a practical wear limit (0.2 m).
m), and becomes practical. When the cutting speed decreases,
The flank wear of the blade material 32 coated with AlO _x having a composition in which the value of x is in the range of 1.0 ≦ x ≦ 1.5 is reduced.

Although the practical wear limit of flank wear is 0.2 mm or less, the practical wear limit of crater wear shown in FIG.
It is desirable that it is 0.1 mm or less. As shown in FIG. 18, the crater wear is reduced by a blade material 32 coated with AlO _x having a composition in which the value of x is in the range of 1.0 ≦ x ≦ 1.5.
At any cutting speed, it is 0.08 mm or less, which is within a range where there is no problem that does not affect the cutter life at about 1/4 of the flank wear.

As described above, the annular milling machine 22 to which the high-speed steel blade material 32 coated with the coating film of AlO _x having the composition of x ≦ 1.0 ≦ x ≦ 1.5 is attached, and the cutting speed is set to 500 m By dry cutting at / min or less, the creation of highly efficient and low cost bevel gears can be realized.

FIG. 19 shows the result of calculating the appropriate thickness of the Al ₂ O ₃ coating. The horizontal axis of FIG. 19 shows the total thickness of the Al ₂ O ₃ . In other words, if Al ₂ O ₃ is a single layer, it represents the film thickness, and if it is a multilayer (with 0.05 μm thick TiN interposed), it represents the total thickness of all films. is there. The vertical axis shows a single layer of Al ₂ O ₃ coating with a film thickness of 1.7
This represents the ratio of the flank wear when the flank wear of the blade material 32 performed in μm is defined as 1. Coating was performed by changing the thickness of the coating film composed of Al ₂ O ₃ in the range of 0.3 μm to 15 μm, and cutting was performed by dry cutting without supplying a cutting oil.

When a layer of Al ₂ O ₃ is coated,
The wear amount increases when the film thickness is less than 0.5 μm and when the film thickness is more than 10 μm. When the film thickness is between 0.5 μm and 10 μm, the ratio of the amount of abrasion is less than 1, which is below the practicable limit. When multi-layer coating of Al ₂ O ₃
When the thickness is 0.5 μm to 10 μm, the abrasion is reduced as compared with the case where a single layer of Al ₂ O ₃ is coated. Therefore, the thickness of the coating film having the composition of Al ₂ O ₃ is at 0.5 [mu] m or more 10
μm or less, and may be a single layer or multiple layers.

FIG. 20 shows the relationship between the cutting speed and the feed rate (mm / bl) that can be accommodated in the flank wear and crater wear that can be practically used. As shown in the figure, when the feed amount was 0.58 mm / bl, the wear was practically possible up to a cutting speed of 450 m / min.

FIG. 21 shows the relationship between the material and hardness of the work and the cutting speed that can be accommodated in practically available flank wear.
That is, as a work 25, a representative variety of carburized and hardened steel gears material (e.g. SCM415, SCM435, SCr420 etc., H _B 120
To H _B 300), carbon steel (e.g. S45C, etc., H _B 150 ~H _B
300) and cast iron (eg FCD50 etc., H _B 150 ~H _B 300
) Is the result of examining the cutting speed range where dry cutting is effective by changing the hardness. FIG. 21 shows the cutting speed at which the flank wear is less than the practical wear limit. From the same figure, it can be seen that in the case of carbon steel, the wear is within the practical wear limit at a cutting speed of 450 m / min or less, and the cutting speed is independent of the work material. It can be seen that the dry cut is effective at 450 m / min or less.

FIG. 22 shows the relationship between the material of the blade member 32 and the cutting speed that can be accommodated in the flank wear that can be practically used. That is, for example, as the material of the blade material 32, SKH51,
SKH55, powdered high-speed steel (1.6% C, 8% W, 6% Mo, etc.), powdered high-speed steel
(2.2% C, 12% W, 2.5% Mo, others), Powdered high speed steel (1.3% C, 6% W,
5% Mo, etc.) and the cutting speed range where dry cutting is effective for various materials was investigated. FIG.
The flank wear indicates a cutting speed below the practical limit, and as shown in the figure, the material of the blade material 32 is SKH51.
In the case of, wear was practically possible up to a cutting speed of 350 m / min.

FIG. 23 shows the relationship between the size of the main body 31 of the annular milling cutter 22 and the cutting speed that can be reduced to a practically usable flank wear. That is, 6 inches (point width 0.06 inches), 9 inches (point width 0.10 inches) and 12 inches (point width 0.14 inches) are applied as the size of the main body 31, and dry cutting is effective for various sizes. This is a study of a wide range of cutting speeds. FIG.
Shows the cutting speed at which the flank wear is below the practical limit, and as shown in the figure, in all sizes, the cutting speed was 400 m / min or less, and the wear was practical.

As described above, AlO _x (1.0 ≦ x ≦ 1.
5) By using an annular milling cutter 22 to which a blade material 32 coated with at least one layer of a film having the following composition is attached and creating a tooth profile by dry cutting at a cutting speed of 500 m / min or less without using a cutting oil, The cutting speed can be greatly improved without using an expensive blade such as a cemented carbide, and a tooth profile can be created.

In the above-described method of processing a gear using the annular milling cutter 22 to which the blade member 32 is attached, it is also possible to perform cutting while blowing air to a cutting portion or a portion other than the cutting portion of the cutter. By performing cutting by the annular milling cutter 22 while blowing air to the cutting portion or a portion other than the cutting portion of the cutter, chips generated by the cutting can be blown off from the cutting portion and removed. It is also possible to mix a small amount of cutting oil into the air and spray it in a mist. By performing the processing of the gear by blowing air, it is possible to realize the creation of the tooth profile at high efficiency and at low cost without causing the chip to be caught.

[0060]

The gear machining method according to the present invention is a gear machining method for forming a tooth profile using a high-speed tool steel gear shaving tool, wherein AlO _x (1.0 ≦ x ≦ 1.5) is used as a basic composition. Gear type tool with at least one layer of film coated on at least flank surface, cutting speed 400m / min
In the following, the tooth profile is created by dry cutting, which does not use cutting oil, so that the cutting speed can be significantly improved without using expensive tools such as cemented carbide and the tooth profile can be created. . As a result, gear machining can be realized with high efficiency and low cost.

Further, the gear machining method of the present invention is a gear machining method in which a gear wheel surface is subjected to finish cutting using a shaving cutter made of high-speed tool steel, wherein AlO _x (1.0 ≦ x
≦ 1.5) at least one layer of a film having a basic composition of at least a tooth surface coated with a shaving cutter,
Finishing of the gear tooth surface by dry cutting, which does not use cutting oil, is used to finish the gear tooth surface by greatly improving the cutting speed without using expensive tools such as cemented carbide. Processing can be performed. As a result, the finishing of the gear tooth surface can be realized with high efficiency and low cost.

Further, the gear machining method of the present invention is a gear machining method for forming a bevel gear using a spiral bevel gear cutter in which a blade material made of high-speed tool steel is attached to a cutter body, wherein AlO _x (1.0 ≦ x ≤1.5) Using a spiral bevel gear cutter equipped with a blade material coated with at least one layer of a film having the basic composition, a tooth profile is created by dry cutting at a cutting speed of 500 m / min or less without using cutting oil. With this configuration, the cutting speed can be greatly improved without using an expensive tool such as a cemented carbide, and the tooth profile of the bevel gear can be created. As a result, bevel gear processing can be realized with high efficiency and low cost.

Since the air is blown to the cutting portion or the portion other than the cutting portion of the cutter to perform the cutting,
Chips and chips generated by the cutting can be blown off from the cutting portion to be removed, so that the tooth shape can be processed at high efficiency and at low cost without causing the chips and chips to bite.

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram of a cutting section of a gear shaper for implementing a gear machining method of the present invention.

FIG. 2 is an external view of a shaving cutter.

FIG. 3 is a graph showing a relationship between a value of x of a material having a composition of AlO _x and flank wear.

FIG. 4 is a graph showing a relationship between a value of x of a material having a composition of AlO _x and crater wear.

FIG. 5 is a graph showing the relationship between coating film thickness and flank wear.

FIG. 6 is a graph showing the relationship between circumferential feed and cutting speed.

FIG. 7 is a graph showing a relationship between a work material and a cutting speed.

FIG. 8 is a graph showing a relationship between a material of a base material and a cutting speed.

FIG. 9 is a graph showing a relationship between a module and a cutting speed.

FIG. 10 is a front view of a shaving cutter for implementing the gear machining method of the present invention.

FIG. 11 is a configuration diagram of a main part of a shaving cutter.

FIG. 12 is a graph showing a relationship between a value of x and a surface roughness of a material having a composition of AlO _x .

FIG. 13 is a graph showing the relationship between the total thickness of Al ₂ O _{3 and} the surface roughness.

FIG. 14 is a graph showing a relationship between a work material and a surface roughness.

FIG. 15 is an overall configuration diagram of a spiral bevel gear grinding machine that implements the gear machining method of the present invention.

FIG. 16 is an external view of an annular milling cutter as a spiral bevel gear cutter.

FIG. 17 is a graph showing a relationship between a value of x of a material having a composition of AlO _x and flank wear.

FIG. 18 is a graph showing a relationship between a value of x of a material having a composition of AlO _x and crater wear.

FIG. 19 is a graph showing the relationship between the total thickness of Al ₂ O ₃ and flank wear.

FIG. 20 is a graph showing a relationship between a feed amount and a cutting speed.

FIG. 21 is a graph showing a relationship between a material of a work and a cutting speed.

FIG. 22 is a graph showing a relationship between a material of a base material and a cutting speed.

FIG. 23 is a graph showing a relationship between a main body size and a cutting speed.

[Explanation of symbols]

 5 Pinion Cutter 11 Shaving Cutter 13 Tooth Surface 22 Annular Milling 32 Blade Material

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Akihide Tsunoya 130 Rikujizo, Ritto-cho, Kurita-gun, Shiga Prefecture Inside Mitsubishi Heavy Industries, Ltd. F term in Kyoto Seiki Seisakusho Co., Ltd. (reference) 3C025 AA11 DD07 EE00 GG03

Claims (4)

[Claims] 1. A gear machining method for creating a tooth profile by using a gear cutting tool made of high-speed tool steel, comprising:
_x (1.0 ≤ x ≤ 1.5) A gear type cutting tool coated with at least one layer of a film having a basic composition of at least flank surface. A cutting tool that cuts at a cutting speed of 400 m / min or less without using a cutting oil. A gear processing method characterized by creating a tooth profile by cutting. 2. A gear machining method in which a gear tooth surface is finish-cut using a shaving cutter made of high-speed tool steel, wherein at least one layer having a basic composition of AlO _x (1.0 ≦ x ≦ 1.5) is formed. A gear cutting method comprising: performing a finish cutting of a gear tooth surface by a dry cut in which a shaving cutter coated on a tooth surface is used without using a cutting fluid. 3. A spiral bevel gear cutter in which a blade material made of high-speed tool steel is attached to a cutter body,
In a gear processing method for creating a bevel gear, AlO _x (1.
0 ≤ x ≤ 1.5) Tooth profile by dry cutting using a spiral bevel gear cutter equipped with a blade material coated with at least one layer of a film having the basic composition, at a cutting speed of 500 m / min or less without using a cutting oil A gear machining method characterized by creating a gear. 4. The gear machining method according to claim 1, wherein air is blown to a part other than the cutting part or the cutting part of the cutter to perform the cutting.