JP2009034787A - Gear machining device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To chamfer an end face angle portion on the tooth face of a ground gear and efficiently machine the end face angle portion while suppressing rise at its vicinity. <P>SOLUTION: This gear machining device 10a has a machining part 12. A combined cutter 100 of the machining part has phrasing cutter portions 40a, 40b for thrusting and chamfering the end face angle portions 30, 31 of teeth 26 of the ground gear 14, and a shaving cutter portion 42 for cutting the tooth face 28 of the ground gear 14. The phrasing cutter portions 40a, 40b and the shaving cutter portion 42 are laid on each other into a disc shape, and the phrasing cutter portions 40a, 40b and the shaving cutter portion 42 are coaxially arranged. The circular shaving cutter portion 42 has a thick main portion 48 and a sub portion 50 thinner than the main portion 48. The phrasing cutter portions 40a, 40b are provided on both side faces of the sub portion 50. The combined cutter 100 engages with the ground gear 14 at an axially crossing angle Ψ which is not zero. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a gear machining apparatus for appropriately chamfering the end face corner portion of a gear.

  Modern automobiles are required to be quiet and durable while having high output, and the gears used for power transmission (for example, transmissions) are more powerful so that power is reliably transmitted and noise is not generated. An accurate tooth surface is desired.

  Such high-precision gears are generally processed by rough cutting with a hob, chamfering, tooth surface formation with a shaving cutter, carburizing and quenching by heat treatment, and grinding and gearing to further improve accuracy. Honing is performed.

  Among these, at the stage where the rough cutting with the hob is completed, the end face corner of the tooth surface is sharp, and as it is, there is a concern that excessive carburization is performed by heat treatment, and the glass is hardened (weakened). For this reason, chamfering is performed to prevent excessive carburization and to improve the gear strength.

  As chamfering, a phrasing cutter that crushes the end face corners of the tooth surface of the gear to be cut is widely used. The phrasing cutter meshes with the work gear without crossing the shaft and crushes the corners of the gear. Examples of a processing method using a phrasing cutter include Patent Document 1 and Patent Document 2. Patent Document 1 discloses that a phrasing cutter meshes with a work gear with an axis crossing angle of 0 °. Patent Document 2 discloses that a phrasing cutter is engaged with a work gear with a predetermined axis crossing angle.

  Patent Document 3 discloses a gear machining device that continuously performs gear cutting and end face processing in one device.

  Patent Document 4 discloses a tool in which a deburring wheel and a spacer including a smoothing wheel for processing a marginal region of the belly are overlapped.

  Patent Document 5 discloses a shaving cutter having a chamfering blade.

JP-A-54-15596 JP-A-61-284318 JP 2006-224228 A JP 2003-19621 A JP 61-8221 A

  As described above, high-precision gears that require high output, quietness, and durability generally require rough cutting, chamfering with a phrasing cutter, tooth surface formation with a shaving cutter, heat treatment, and gear grinding. Gear honing is performed.

  In chamfering with a phrasing cutter, the end face corners of the tooth surface can be properly chamfered, but basically the crushing process results in the surplus being pushed out to the side, and the rise due to the surplus Occurs.

  Such a raised part can be removed by grinding in a subsequent grinding process, but heat treatment is performed before the grinding process, and the raised part is considerably harder. The applied load is large and the grinding takes time. In addition, it is desirable that the grinding process is costly from the viewpoint of production efficiency and can be omitted.

  If the grinding process is omitted, the load on the grindstone is extremely large in the subsequent gear honing process, which is not preferable. After the heat treatment, the hardness of the machined gear is high, and the gear honing wheel and the machined gear are in contact with each other during machining, and only the part that contacts the raised part is extremely worn. It is.

  In the tool described in Patent Document 2, the phrasing cutter is meshed with the work gear with a predetermined crossing angle. However, if the crossing angle is inadvertently provided, the end of the teeth of the phrasing cutter is covered. It interferes with the tooth surface of the cutting gear. Moreover, this tool is provided with serrations as cutting blades on the tooth surface, and is difficult to manufacture.

  In addition, the shaving process performed after the chamfering process also has an effect of suppressing the swell, but it takes a considerable amount of time than the chamfering process, and the so-called tact time becomes longer. There may be a waste of waiting time before doing so.

  On the other hand, even for gears that require relatively low accuracy and are not heat-treated, if the tooth surface finish such as shaving is performed without taking measures against the raised portion generated by chamfering of the phrasing cutter, the raised portion will be applied to the tool. The tool life is inevitably shortened due to the load. As a result, the number of times that the machine tool is stopped for the tool change operation, the number of times of maintenance and inspection increases, and there is a concern about an increase in tool costs.

  In the shaving cutter described in Patent Document 5, the crest can be chamfered along the tooth width direction, but the end surface in the tooth width direction cannot be chamfered. In addition, machining must be performed while shifting the position of the shaving cutter with respect to the work gear.

  The present invention has been made in consideration of such problems, and an object of the present invention is to provide a gear machining apparatus capable of appropriately chamfering the end face corner portion of the tooth surface and performing efficient machining. To do.

  The gear machining apparatus according to the present invention has the following features.

  1st characteristic: The workpiece support part which pivotally supports a cutting gear, and the cutter support part which pivotally supports this composite cutter so that a composite cutter may be meshed | engaged with the said cutting gear provided in the said workpiece support part. The cutter support unit meshes the phrasing cutter with the work gear with an axis crossing angle ψ (ψ ≠ 0), and the composite cutter has a phrasing cutter unit and a shaving cutter unit, The phrasing cutter part and the shaving cutter part have an arc part having a plurality of machining teeth and are overlapped to form a disk shape, and the arc parts of the phrasing cutter part and the shaving cutter part are arranged coaxially It is characterized by being.

  According to such a gear machining apparatus, the end face corner portion of the tooth surface can be chamfered by the phrasing cutter portion of the composite cutter, and the occurrence of swell in the vicinity of the end face corner portion can be suppressed by the shaving cutter portion. Further, the chamfering process and the shaving process can be performed simultaneously, and the subsequent shaving process of the second process can be omitted or the time can be shortened. Here, the arc is a shape including a circle.

  2nd characteristic: It has a 1st process part and a 2nd process part which move relatively with respect to the said workpiece | work support part, and processes it in order, The said cutter support part and the said composite cutter are said 1st process. The second process unit may include a shaving cutter that processes a tooth surface of the work gear.

  Thus, in one gear processing apparatus, the chamfering process and the first shaving process by the composite cutter can be performed in the first process part, and the second shaving cutter process can be performed in the second process part. It is.

  In general, the shaving process takes more time than the chamfering process by the phrasing cutter, but the time of the first process can be shortened by performing the shaving process in the first process and the second process. Moreover, the tact time can be shortened by setting the first step and the second step to substantially the same time.

  3rd characteristic: The said workpiece | work support part may be provided in the turntable which adjusts direction with respect to the said 1st process part. An appropriate axis crossing angle ψ according to the work gear can be set by the turntable.

  Fourth feature: A helical gear is applicable as the work gear.

  Fifth feature: the work gear may be a gear of a vehicle transmission. The gear machined by the gear machining apparatus of the present invention has high accuracy, is excellent in quietness and durability, and is suitable for a vehicle transmission.

  Sixth feature: The composite cutter and the shaving cutter may be provided in a turret mechanism, and may be moved sequentially to a position facing the workpiece support portion by the rotation of the turret mechanism to process the work gear. By using the turret mechanism, it is possible to perform chamfering with a composite cutter and processing of a tooth surface with a shaving cutter in one gear machining apparatus, which is efficient.

  7th characteristic: The said work support part may be provided under the said turret mechanism, and the said phrasing cutter and the said shaving cutter may be meshed | engaged with the said cutting gear by the said turret mechanism descend | falling. Thereby, the weight of the turret mechanism can be used for meshing and pressing between the work gear and the tool.

  Eighth feature: The rotation axis of the turret mechanism may have an axis crossing angle ψ with respect to the axis of the workpiece support portion. That is, since both the phrasing cutter and the shaving cutter are engaged with the work gear with an axis crossing angle, the turret mechanism itself can be set obliquely, resulting in a simple configuration.

  Ninth feature: The distance between the shafts of the shaving cutter unit and the phrasing cutter unit and the work gear may be matched.

  Tenth feature: The work support portion may not have a rotational drive source of the work gear, and the work gear may be configured to mesh with the composite cutter. As a result, the number of rotational drive sources is reduced and the construction is simplified, and the work gear is rotated around the composite cutter having a relatively large inertia, thereby shortening the acceleration / deceleration time.

  Eleventh feature: a chamfering process and a deburring process when a roller cutter unit for deburring by bringing two roller cutters into contact with the work gear from a direction different from the cutter support portion. This can be done at the same time to shorten the processing time.

  In this case, the shaving cutter part may be circular, and may have a main part and a sub part thinner than the main part, and the phrasing cutter part may be disposed so as to overlap the sub part.

  As a result, while the composite cutter makes one round, the work gear is always shaved by either the main portion or the sub portion, which is efficient. Moreover, the main part is thick, and the entire tooth surface of the work gear can be shaved.

  Further, the combined total number of teeth of the phrasing cutter unit and the shaving cutter unit may be set to be different from the number of teeth of the work gear or a multiple thereof. During multiple rotations, it is possible to prevent specific combinations of the teeth of the composite cutter and the teeth of the work gear from coming into contact with each other. Processing. Therefore, a well-balanced process can be performed without deviation.

  Furthermore, the number of teeth of the main part may be larger than the number of teeth of the sub part. In general, since shaving requires a longer time than chamfering, the portion occupied by the shaving cutter portion is made larger than the portion occupied by the phrasing cutter portion, so that balanced processing is possible.

  If the phase adjusting mechanism between the teeth of the phrasing cutter unit and the shaving cutter unit is provided, the phrasing cutter unit and the shaving cutter unit can be set in appropriate directions with respect to the work gear.

  If the arc portion of the phrasing cutter portion is 90 ° to 180 °, the shaving cutter portion is well balanced.

  When the phrasing cutter part has a contour shape cut by a straight line connecting the arc part and both ends of the arc part in a side view, the phrasing cutter part can be easily manufactured.

  According to the gear machining apparatus according to the present invention, the end face corner portion of the tooth surface can be chamfered by the phrasing cutter portion of the composite cutter, and the occurrence of bulge in the vicinity of the end face corner portion can be suppressed. Further, the chamfering process and the shaving process can be performed at the same time, and the subsequent second shaving process can be omitted or the time can be shortened.

  Embodiments of the gear machining apparatus according to the present invention will be described below with reference to FIGS. The gear machining apparatus according to the present embodiment performs chamfering on the end face corner portion of the work gear that has finished the coarse gear cutting process by the hob and also performs shaving of the tooth surface.

  Regarding the gear machining apparatus 10a (see FIG. 20) and 10b (see FIG. 21) according to the present embodiment, first, a work gear 14 to be machined, a composite cutter 100 as a tool to be used, and machining by the composite cutter 100 The unit 12 (see FIG. 5) will be described.

  The work gear 14 is, for example, a gear of a vehicle transmission. The gears machined by the gear machining devices 10a and 10b have high accuracy, are excellent in quietness and durability, and are suitable for vehicle transmissions.

  As shown in FIG. 1, the work gear 14 is a helical gear, for example, and has a plurality of teeth 26. In the state in which the work gear 14 is coarsely cut, left and right end face corners 30 and 31 of the tooth surface 28 have sharp edges 33 (see FIG. 8A). In the composite cutter 100, the sharp portion 33 is chamfered. The work gear 14 processed by the composite cutter 100 is not limited to a helical gear, and may be a spur gear or the like.

  As shown in FIGS. 2, 3, and 4, the composite cutter 100 includes two phrasing cutter portions 40 a and 40 b that are chamfered by pressing the end face corner portions 30 and 31 of the work gear 14, and the work gear. A shaving cutter portion 42 for cutting the 14 tooth surfaces 28.

  A plurality of serrations 46 serving as cutting blades are provided on the tooth surfaces of the respective processing teeth 44 of the shaving cutter unit 42. The serration 46 extends at a right angle to the tooth width direction, in other words, in a direction from the tooth bottom toward the tooth tip. As will be described later, the composite cutter 100 is engaged with the workpiece gear 14 so as to intersect with the axis crossing angle ψ for machining. As a result, the machining teeth 44 abut against the tooth surface 28 of the work gear 14 so as to rub slightly in the lateral direction, and the serration 46 can cut the tooth surface 28. This cutting is for shaping the tooth surface 28, and is classified as finish cutting, unlike rough cutting with a hob or the like.

  The shaving cutter part 42 includes a thick main part 48, a sub part 50 thinner than the main part 48, a shaft hole 52, a plurality of through holes 54 for weight reduction, and two sub parts 50 provided in the sub part 50. A fixing bolt hole 56 and a reference hole 58 are provided. The processing teeth 44 are provided over the entire circumference of the shaving cutter portion 42, and are thick at the main portion 48 and thin at the sub portion 50.

  As a result, while the composite cutter 100 makes one round, the work gear 14 is always shaved by either the main portion 48 or the sub portion 50 and is efficient. Further, the main portion 48 has a large width, so that almost the entire tooth surface 28 of the work gear 14 can be shaved.

  The processing teeth 44 do not have to be provided on the entire circumference, and may be provided only on the main portion 48, for example. In this case, the sub part 50 has a function as a spacer without the processing teeth 44.

  The phrasing cutter portion 40a includes an arc portion 60 provided with a plurality of processing teeth 32a, a shaft recess 62, two long holes 64 that are long in the circumferential direction, and a reference long hole (phase adjustment mechanism) 66 that is long in the radial direction. And a central convex portion 67a. The shaft recess 62 forms a hole that supports the shaft J2 (see FIG. 5) together with the shaft hole 52 in a side view. The central convex portion 67a has a low semi-cylindrical shape and is fitted with the corresponding concave portion 67b of the shaving cutter portion 42 to center the phrasing cutter portion 40a.

  The arc portion 60 is slightly smaller than 180 ° with respect to the entire composite cutter 100. When the angle of the arc portion is 90 ° to 180 °, the shaving cutter portion 42 is well balanced.

  In a side view, the phrasing cutter portion 40a has a contour shape cut by an arc portion 60 and a straight line L1 connecting both ends S1 and S2 of the arc portion 60. Thereby, the phrasing cutter parts 40a and 40b are obtained in one process of cutting the phrasing cutter along the straight line L1, and are easy to manufacture.

  The phrasing cutter unit 40b has a target structure other than the processing teeth 32b with respect to the phrasing cutter unit 40a. The processing teeth 32 b are formed so as to be suitable for processing the end face corner portion 31.

  In the composite cutter 100, phrasing cutter portions 40a and 40b are superimposed on both side surfaces of the sub portion 50. Thereby, the processing teeth 32a and the processing teeth 32b are separated according to the thickness of the work gear 14, the composite cutter 100 and the work gear 14 rotate while meshing, and the processing teeth 32a of the phrasing cutter portion 40a are rotated. By pressing against the end face corner portion 30, the sharp portion 33 is crushed and chamfered. The processing teeth 32b of the phrasing cutter part 40b press against the other end face corner part 31 to crush the sharp part 33 and chamfer it.

  Conventionally, the phrasing cutter is meshed with the work gear 14 with the axis crossing angle ψ set to ψ = 0, but the framing cutter portions 40a and 40b of the composite cutter 100 are arranged so as to overlap the shaving cutter portion 42. Therefore, like the shaving cutter part 42, the axis crossing angle ψ becomes ψ ≠ 0, which seems to be inconvenient at first glance. However, by causing the phrasing cutter portions 40a and 40b to cross the work gear 14 in a state where ψ ≠ 0, the occurrence of the raised portion 80 (see FIG. 14) can be appropriately suppressed. This will be described later.

  The two long holes 64 are provided at positions corresponding to the fixing bolt holes 56, and the fixing bolts 70 are inserted therethrough. The fixing bolt 70 passes through the long hole 64 and the fixing bolt hole 56 of the phrasing cutter portions 40 a and 40 b, protrudes to the opposite surface, and is fixed by the nut 72. The phrasing cutter portions 40a and 40b can move in the circumferential direction within the range of the length of the long hole 64, and can adjust their positions.

  An adjustment bolt (phase adjustment mechanism) 74 is inserted into the reference long hole 66 and the reference hole 58. The adjustment bolt 74 has a head 74a, a rod portion 74b coaxial with the head 74a, and an eccentric portion 74c provided at the tip of the rod portion 74b. A retaining member 74d is attached to the eccentric portion 74c.

  The rod portion 74 b is inserted through the reference hole 58, and the eccentric portion 74 c is inserted through the reference long hole 66. That is, by rotating the adjustment bolt 74, the eccentric part 74c is eccentric in the reference long hole 66, and the phrasing cutter part 40a can be displaced by a minute amount in the circumferential direction. According to such a phase adjustment mechanism, the phase can be finely adjusted, and the phrasing cutter units 40a and 40b and the shaving cutter unit 42 can be set in appropriate directions with respect to the work gear 14, respectively. After this adjustment, the phrasing cutter parts 40a and 40b may be fixed to the shaving cutter part 42 by using the fixing bolt 70.

  The phrasing cutter units 40a and 40b and the shaving cutter unit 42 are overlapped to form a disk shape, and the arc portions of the phrasing cutter units 40a and 40b and the shaving cutter unit 42 are arranged coaxially.

  According to such a composite cutter 100, the end face corner portions 30 and 31 of the tooth surface are chamfered by the phrasing cutter portions 40a and 40b, and the raised portion 80 in the vicinity of the end face corner portions 30 and 31 by the shaving cutter portion 42 (see FIG. 14) can be suppressed. Further, the chamfering process and the shaving process can be performed at the same time, and the subsequent second shaving process can be omitted or the time can be shortened.

  In the composite cutter 100, the combined total number of teeth of the phrasing cutter units 40a and 40b and the shaving cutter unit 42 is different from the number of teeth of the work gear 14 or a multiple thereof. As a result, a specific combination of the teeth of the composite cutter 100 (that is, the machining teeth 44 or 32a, 32b) and the teeth 26 of the work gear 14 are in contact with each other while the work gear 14 rotates a plurality of times. The different teeth of the composite cutter 100 abut on each tooth of the work gear 14 in order to perform machining. Therefore, a well-balanced process can be performed without deviation.

  In addition, the number of teeth of the phrasing cutter portions 40a and 40b that are not combined with the shaving cutter portion 42 (96 in FIG. 2) is larger than the number of teeth of the shaving cutter portion 42 (47 in FIG. 2). It is.

  The number of teeth of the main part 48 may be set larger than the number of teeth of the sub part 50. In general, since the shaving process requires a longer time than the chamfering process, the portion occupied by the main portion 48 of the shaving cutter portion 42 is made larger than the portion occupied by the phrasing cutter portions 40a and 40b, and a balanced processing is possible. Become.

  Next, the processing unit 12 that processes the work gear 14 by applying the composite cutter 100 will be described.

  As shown in FIG. 5, the machining unit 12 includes a shaft J1 as a workpiece support unit that pivotally supports the work gear 14, a composite cutter 100, and an axis J2 as a cutter support unit that pivotally supports the composite cutter 100. Have The axis J2 can be rotated by a drive source (not shown). The axis J <b> 1 is rotated when the work gear 14 meshes with the composite cutter 100.

  The shaft J2 pivotally supports the composite cutter 100 so that the composite cutter 100 is engaged with the work gear 14 provided on the shaft J1. The axis J2 meshes the composite cutter 100 with the workpiece gear 14 with a non-zero axis crossing angle ψ, and the machining teeth 32a and 32b of the phrasing cutter portions 40a and 40b are the tooth surfaces 28 of the teeth 26 of the workpiece gear 14. (See FIG. 6). The axis crossing angle ψ is an angle formed by the axis J1 of the work gear 14 and the axis J2 of the composite cutter 100 (see FIG. 6).

  As is clear from FIG. 5, since the composite cutter 100 is provided on a single axis J2, the distance between the axis J2 of the shaving cutter portion 42 and the axis J1 of the work gear 14 is determined by the phrasing cutter portion. The inter-axis distances between the axis J2 of 40a and 40b and the axis J1 of the work gear 14 are equal.

  As shown in FIG. 6, the machining teeth 32a and the machining teeth 32b are separated according to the thickness of the work gear 14, and the composite cutter 100 and the work gear 14 rotate while meshing with each other, so that the phrasing cutter unit 40a The processing teeth 32a press against the end face corners 31 to crush the sharp parts.

  FIG. 6 shows a relative positional relationship between the teeth 26 of the work gear 14 and the processing teeth 32a and 32b of the phrasing cutter parts 40a and 40b. The work gear 14 and the phrasing cutter parts 40a and 40b are connected to each other. It is the schematic diagram developed along the peripheral surface, respectively. As apparent from FIG. 6, the work gear 14 and the phrasing cutter portions 40 a and 40 b have an axis crossing angle ψ and intersect at an angle. 6, 12, and 13, only the processing teeth 32 a and 32 b of the phrasing cutter parts 40 a and 40 b are shown in the composite cutter 100, and the shaving cutter part 42 is omitted.

  On the other hand, as shown in FIG. 7, there is no axis crossing angle ψ in the meshing according to the prior art.

  Next, the effect | action which the processing tooth 32a of the phrasing cutter part 40a presses with respect to the end surface corner | angular part 31, and crushes the sharp part 33 is demonstrated. Here, in order to facilitate understanding, the cutting action by the shaving cutter unit 42 is omitted.

  The work gear 14 rotates in the right direction in FIG. 6, that is, in the direction of the arrow A1, and the composite cutter 100 rotates in the oblique direction, that is, in the direction of the arrow A2 by an angle ψ.

  As shown in FIG. 8A, the processing tooth 32 a of the phrasing cutter portion 40 a first comes into contact with the point P <b> 1 at the substantially top portion of the end face corner portion 30 of the tooth 26. At the initial stage of meshing at this time, the processing teeth 32a are inclined diagonally to the right with respect to the teeth 26, and the front side of the center line C is in contact with the portion P1. At this time, a sharp portion 33 exists in the end face corner portion 30. 8A to 8C, a center line C is added to the tooth surface of the processing tooth 32a for easy understanding. The meshing at this time corresponds to the meshing shown by arrow B1 in FIG.

  As shown in FIG. 8B, in the middle stage of the meshing, the processing teeth 32 a of the phrasing cutter portion 40 a are in contact with a place P <b> 2 having a substantially intermediate height of the teeth 26. In the middle stage of meshing, the processing teeth 32a are substantially parallel to the teeth 26, and the center line C abuts on the location P2. At this time, the upper portion of the portion P2 is chamfered and the sharp portion 33 is chamfered, but the sharp portion 33 remains below the portion P2. The meshing at this time corresponds to the meshing shown by the arrow B2 in FIG.

  As shown in FIG. 8C, at the end of the meshing, the processed tooth 32 a of the phrasing cutter portion 40 a comes into contact with the position P <b> 3 at the substantially bottom portion of the tooth 26. At the end of meshing, the processing teeth 32a are inclined obliquely to the left with respect to the teeth 26, and the back of the center line C abuts on the place P3. At this time, the end face corner portion 30 is chamfered over the entire length, and the sharp portion 33 is chamfered. The meshing at this time corresponds to the meshing shown by the arrow B3 in FIG.

  As shown in FIG. 9, an elongated involute surface is formed at the chamfered end surface corner portion 30, and the sharp portion 33 is chamfered. Here, as shown by the arrow D1, the locus of movement of the processing tooth 32a is an oblique direction and includes a lateral movement component.

  The movement trajectory of the tooth surface of the phrasing cutter at the end face corner 30 is shown in more detail in FIGS. 10A and 10B. 10A shows a case where the axis crossing angle ψ is 5 °, and FIG. 10B shows a case where the axis crossing angle ψ is 8 °. Reference symbol Z indicates a meshing circle between the work gear 14 and the phrasing cutter portions 40a and 40b. As understood from FIGS. 10A and 10B, the movement locus contains a considerable amount of the lateral component, and this component is larger when the axis crossing angle ψ is 8 ° than when it is 5 °. The larger the transverse component, the better the normal machinability.

  On the other hand, in the meshing according to the prior art (see FIG. 6), there is no axis crossing angle ψ (that is, ψ = 0), so the locus of movement of the machining teeth 32a is indicated by an arrow E in FIG. As shown, the lateral movement component is not included.

  Since the phrasing cutter parts 40a and 40b mesh with the work gear 14 with an axis crossing angle ψ, the phrasing cutter parts 40a and 40b not only crush the end face corner part 30 of the work gear 14 and chamfer the sharp part 33, but also lateral movement components. Sliding between the surfaces containing the occurs. Thereby, generation | occurrence | production of the surplus swell in the location 82 (refer FIG.9 and FIG.11) adjacent to a chamfering part among the tooth surfaces 28 can be prevented, or it can suppress.

  Further, the tooth surfaces of the processing teeth 32a of the phrasing cutter portions 40a and 40b are intended to press and slide with respect to the end surface corner portion 30. Therefore, the tooth surfaces of the phrasing cutter portions 40a and 40b are involute surfaces having no corner portions, and are easy to manufacture.

  Although a detailed description is omitted, the sharp end portion 33 is appropriately chamfered by the processing teeth 32b of the phrasing cutter portions 40a and 40b on the opposite end face corner portion 31 of the work gear 14, and the chamfered portion is also chamfered. Generation | occurrence | production of the surging of the surplus meat in the adjacent location 82 (refer FIG. 11) can be prevented or suppressed. In this case, as shown by the arrow D2 in FIG. 11, the locus of movement of the processing teeth 32b is an oblique direction and includes a lateral movement component, and the same effect as the processing on the end face corner portion 30 is obtained. It is done. The details of the trajectory of this movement are the opposite directions of the arrows in the case shown in FIGS. 10A and 10B.

  By the way, in the meshing according to the prior art, there is generally no axis crossing angle ψ (see FIG. 7). The reason for this is that it is not possible to overlook the surging of the surplus that occurs at the location 82 (see FIG. 9) adjacent to the chamfered portion, or to provide an effective axis crossing angle ψ as a solution. It depends.

  In the device described in Patent Document 2, an axis crossing angle ψ is provided, but it is actually not easy to chamfer the end face corners 30 and 31 by serration.

  Further, providing the axis crossing angle ψ may cause the machining teeth 32a and 32b of the phrasing cutter portions 40a and 40b to interfere with the tooth surface 28 of the tooth 26 of the work gear 14 (see the phantom line in FIG. 7). One of the reasons is that the setting is difficult.

  The present inventor found the following expression (1) as an appropriate setting of the axis crossing angle ψ.

  Here, the upper left side is the amount of interference with the phrasing cutter parts 40a and 40b of the work gear 14, and interference can be avoided by setting the machining teeth 32a and 32b to be thin by the value indicated by the upper left side. it can. The right side shows the cosine component of the tip width of the processed teeth 32a and 32b.

In the equation (1), as shown in FIG. 12, l ₁ is a chamfering width, l ₂ is a lapping amount, BOG is a gear deflection angle, and SBG is a meshing circular arc tooth thickness. DBG is a gear meshing swing angle.

  As shown in FIG. 13, DBG is the gear mesh diameter of the work gear 14, DKG is the tooth tip diameter of the work gear 14, and DBC is the gear mesh diameter of the phrasing cutter portions 40a and 40b. , DKC is the tooth tip diameter of the phrasing cutter portions 40a, 40b. Zg is the number of teeth of the workpiece gear 14, and SKC is the tip thickness of the processing teeth 32a and 32b of the phrasing cutter portions 40a and 40b. α is a margin.

  When the above equation (1) is arranged, the following equation (2) is obtained.

  That is, by setting the axis crossing angle ψ to a value represented by the expression (2), it is possible to more reliably prevent the machining teeth 32a and 32b of the phrasing cutter portions 40a and 40b from interfering with the work gear 14.

  Next, the experimental results of processing by the processing unit 12 configured as described above will be described. In these experiments, the phrasing cutter parts 40a and 40b are provided on the entire circumference of 180.degree. Without the shaving cutter part 42, particularly in order to confirm the functions of the phrasing cutter parts 40a and 40b. The experiment was conducted while changing the axis crossing angle ψ of the phrasing cutter.

  FIG. 14 is an enlarged view of the end face corner portion 30 (right tooth surface) obtained by chamfering with the axis crossing angle ψ set to ψ = 0 as in the prior art. As can be understood from FIG. 14, a raised portion 80 due to a surplus wall is recognized at a location near the chamfered portion (see a location 82 in FIG. 8). The height of the raised portion is H1, and the width is H2. The results for the right and left tooth surfaces after a predetermined number of machining operations for ψ = 0 are shown in the column “ψ = 0 °” in Tables 1 and 2. A tracer or the like was used for the measurement.

  FIG. 15 is an enlarged view of the end face corner 30 (right tooth surface) that has been chamfered with an axis crossing angle ψ set to ψ = 5 °. As can be understood from FIG. 15, the occurrence of the raised portion 80 is considerably suppressed. The results for the right tooth surface and the left tooth surface obtained by performing a predetermined number of machining operations for ψ = 5 ° are shown in the column “ψ = 5 °” in Tables 1 and 2.

  FIG. 16 is an enlarged view of the end face corner portion 30 (right tooth surface) chamfered with the axis crossing angle ψ set to ψ = 8 °. As can be understood from FIG. 16, the raised portion 80 is almost eliminated. The results for the right tooth surface and the left tooth surface obtained by performing a predetermined number of machining operations for ψ = 8 ° are shown in the column “ψ = 8 °” in Tables 1 and 2. In Tables 1 and 2, the negative value is 0.

  FIG. 17 is an enlarged view of the end face corner portion 30 (right tooth surface) of the 2000th workpiece gear 14 by chamfering the 2000 workpiece gears 14 with the axis crossing angle ψ being ψ = 5 °. is there. As can be understood by comparing FIG. 15 and FIG. 17, the rising portion 80 hardly changes between the initial stage and the 2000th. In addition, after 2000 machining operations were performed, the shapes of the machining teeth 32a and the machining teeth 32b were measured precisely. As a result, no wear was observed compared to the first machining operation.

  Next, the analysis result performed about the value of the axis crossing angle (psi) of the process part 12 in the gear processing apparatus comprised in this way is demonstrated.

  As shown in FIG. 18, when the axis crossing angle ψ is set large, the machining teeth 32 a interfere with the teeth 26 of the work gear 14, and therefore, a flank 300 that is substantially parallel to the machining teeth 32 a may be provided at the rear end portion. Has been done. By providing such a flank 300, the axis crossing angle ψ can be increased and efficient machining becomes possible. FIG. 18 shows the shape of the machining teeth 32a in which the remaining cutter width S3 is secured with respect to the cutter blade width S in consideration of the interference amount S1 and the gap S2 in consideration of the interference of the teeth 26 of the work gear 14. Yes.

  By the way, it is preferable that the remaining cutter width S3 is 0.4 mm or more from the viewpoint of strength. The gap S2 is preferably set to about 0.5 mm in consideration of errors and the like. Table 3 shows the results of analysis and calculation of the relationship among the axis crossing angle ψ, the interference amount S1, the cutter blade width S, and the remaining cutter width S3 under standard conditions. Here, the gap S2 is 0.5 mm.

  As apparent from Table 3, when the axis crossing angle ψ is 8 °, the remaining cutter width S3 is 0.42 mm, and the strength is ensured. When the axis crossing angle ψ is 9 °, the remaining cutter width S3 is 0.38 mm, and the strength may be insufficient. That is, from the viewpoint of strength, it is desirable that the axis crossing angle ψ is ψ ≦ 8 °.

  When the axis crossing angle ψ is 4 °, it is considered that the remaining cutter width S3 is 0.54 mm and has sufficient strength, but the processing efficiency is lowered. In order to suppress the occurrence of swell of the chamfered portion in the work gear 14, it is considered that the effect is higher as the movement locus of the tooth surface 32 a of the phrasing cutter 18 in the end face corner portion 30 is lateral.

  As shown in the simulation result of FIG. 19A, when the axis crossing angle ψ is ψ = 4 °, the movement trajectory of the tooth surface 32a has a considerably steep slope depending on the place, the lateral component is small, and the rising portion is generated. Suppressive effect is low.

  As shown in the simulation result of FIG. 19B, when the axis crossing angle ψ is ψ = 5 °, the movement trajectory of the tooth surface 32a becomes moderate to some extent, and there is a lateral component to some extent, which has the effect of suppressing the occurrence of the bulging portion. is there.

  As shown in the simulation result of FIG. 19C, when the axis crossing angle ψ is ψ = 6 °, the movement trajectory of the tooth surface 32a is considerably gradual, and there are many lateral components, which has the effect of suppressing the occurrence of the bulging portion. high. That is, in order to obtain the effect of suppressing the occurrence of the swelled portion, it is desirable that the axis crossing angle ψ is ψ ≧ 5 °.

  As a result, in order to satisfy the strength and processing effect of the processing teeth 32a, the axis crossing angle ψ is preferably in the range of 5 ° to 8 °.

  Next, the gear machining apparatuses 10a and 10b having the machining section 12 will be described.

  As shown in FIG. 20, the gear machining apparatus 10a according to the first embodiment performs chamfering and shaving of a plurality of work gears 14 at the same time, and intermittently turns the work gears 14 every 90 °. A feed table 101 to be rotated, a first stage (first process section) 102 that performs chamfering and shaving with the composite cutter 100 on the work gear 14, and a second shaving process on the work gear 14. A second stage (second process section) 104, a third stage 106 for performing a third shaving process on the workpiece gear 14, and a carry-in / out stage 108 for exchanging the workpiece gear 14. The feed table 101 rotates horizontally, for example.

  The feed table 101 includes four rotation shafts (work support portions) 110a, 110b, 110c, and 110d that can support the workpiece gear 14 at equal intervals (90 °) near the outer periphery, and each is rotated by a motor (not shown). Is possible. The four rotating shafts 110a to 110d may be rotated independently by four motors, or may be rotated by distributing driving force by one motor. Of the rotary shafts 110a to 110d, the one on the loading / unloading stage 108 is stopped for loading / unloading the work gear 14, and the corresponding motor is stopped or the clutch is turned off.

  The first stage 102 is a stage for chamfering the end face corner portions 30 and 31 of the work gear 14 by the phrasing cutter portions 40a and 40b, and performing the shaving processing by the shaving cutter portion 42, and the processing portion 12 described above. (See FIG. 5). As described above, the processing unit 12 has the composite cutter 100 and meshes the composite cutter 100 with the work gear 14 with an intersection angle ψ. The composite cutter 100 can advance and retreat in the radial direction as viewed from the feed table 101, meshes with the work gear 14 when chamfering the work gear 14, and retracts outward when the feed table 101 is rotated. The shaving process of the first stage 102 corresponds to rough finishing.

  The second stage 104 is a stage for performing a second shaving process on the tooth surface 28 of the work gear 14, and has a shaving cutter 112. The shaving cutter 112 can advance and retreat in the radial direction when viewed from the feed table 101, meshes with the work gear 14 when machining the work gear 14, and retracts outward when the feed table 101 is rotated. The shaving process of the second stage 104 corresponds to precision finishing.

  The shaving cutter 112 of the second stage 104 may have the same teeth as the shaving cutter portion 42 of the composite cutter 100 in the first stage 102, or may be different suitable for precision finishing.

  The third stage 106 is a stage for performing a third shaving process on the tooth surface 28 of the work gear 14, and includes a shaving cutter 114. The shaving cutter 114 can advance and retreat in the radial direction as viewed from the feed table 101, meshes with the work gear 14 when machining the work gear 14, and retracts outward when the feed table 101 is rotated. The shaving process of the third stage 106 corresponds to further precision finishing.

  The work gear 14 can process the tooth surface 28 with high precision by the shaving cutter portion 42 of the composite cutter 100 of the first stage 102. Depending on the design conditions (tact time, etc.), the second stage 104 and the second stage One or both of the three stages 106 may be omitted.

  The rotary shafts 110a, 110b, 110c, and 110d that support the work gear 14 are configured to be vertical, while the tools of the first stage 102, the second stage 104, and the third stage 106 are It may be provided obliquely so as to have an axis crossing angle ψ. This angle should be adjustable.

  The work gear 14 that has been processed up to the third stage 106 is sent to the carry-in / carry-out stage 108, taken out of the gear processing apparatus 10a, and sent to the next processing (for example, heat treatment processing).

  According to the gear machining apparatus 10a configured as described above, the chamfering process and the first shaving process by the composite cutter 100 are performed by the first stage 102 in one apparatus, and the second stage 104 and the third stage 106 are performed. Further tooth surface processing by the shaving cutters 112 and 114 can be performed, which is efficient. That is, it is not necessary to transfer the workpiece gear 14 between the chamfering process and the shaving process, and the chamfering process and the shaving process are integrated into one apparatus and save space.

  Further, since the composite cutter 100 meshes with the work gear 14 with an axis crossing angle ψ, not only chamfering is performed on the end face corner portions 30 and 31 of the work gear 14 but also crushing is caused. The occurrence of meat swell can be suppressed.

  In addition, the rotation shafts 110a to 110d as work support portions are provided according to the first stage 102, the second stage 104, the third stage 106, and the carry-in / carry-out stage 108, and the three work gears 14 are connected to the first work gear 14. The stage 102, the second stage 104, and the third stage 106 can be processed simultaneously.

  In general, the shaving process takes more time than the chamfering process by the phrasing cutter, but the first stage 102 and the second stage 104 are omitted by omitting the first stage 102 to the third stage 106 (or the third stage 106). ), The processing time of the first stage 102 can be shortened. Further, the processing time in the first stage 102, the second stage 104, and the third stage 106 (when the third stage 106 is omitted, the processing in the first stage 102 and the second stage 104) is set to substantially the same time. Thus, the tact time can be shortened.

  Although the gear machining apparatus 10a has three machining stages except for the carry-in / carry-out stage 108, the number of machining stages for the work gear 14 may be two or four or more. In other words, at least processing by the composite cutter 100 of the first stage 102 can be performed with considerably high efficiency. When the number of processing stages is four or more, for example, a hobbing processing stage may be provided in front of the first stage 102.

  Next, the gear machining apparatus 10b according to the second embodiment will be described. In the description of the gear processing apparatus 10b, the transverse direction is the X direction, the depth direction is the Y direction, and the height direction is the Z direction.

  As shown in FIG. 21, the gear machining apparatus 10b includes a rotary table (rotary base) 202 provided on a base table 200, a work support unit 204 provided on the rotary table 202, a drive board 206, And a tool support 208 provided adjacent to the drive panel 206. In FIG. 20, the operation panel, the lubrication device, the hydraulic power source, the coolant, and the like of the gear machining device 10b are not shown.

  The workpiece support unit 204 includes an X slide base 210 provided on the rotary table 202, an X slider 212 that slides in the X direction with respect to the X slide base 210, and the work gear 14 on the X slider 212 from the left and right. A head stock 214 and a tail stock 216 that are rotatably supported, and a roller cutter unit 220 that is provided in the back in the Y direction and deburrs the work gear 14. The X slider 212 is movable under the action of the X motor 219 in the longitudinal direction of the X slide base 210 (in the X direction when ψ = 0. Hereinafter, it is also simply referred to as the X direction).

  The slide base 210 is provided with a base rotation motor 222. Under the action of the base rotation motor 222, the slide base 210 rotates with respect to the rotary table 202 in a horizontal plane. As a mechanism for rotating the slide base 210 relative to the rotary table 202, for example, a worm wheel mechanism is used. The rotary table 202 is provided with a sensor (for example, a rotary encoder) 224 that accurately measures the amount of rotation of the slide base 210, and the slide base 210 is moved by performing feedback of a fully closed system based on the signal of the sensor 224. Accurate positioning control can be performed. That is, since the amount of rotation of the slide base 210 is directly detected by the sensor 224 instead of indirect feedback based on the amount of rotation of the base rotation motor 222 (so-called semi-closed control), precise control is possible.

  The rotary table 202 is provided with a plurality of (for example, four) clamps 226 that fix the slide base 210 for which positioning control has been completed. The clamps 226 are provided at equal intervals around the rotary table 202 (only one unit is shown in FIG. 20). The rotation of the slide base 210 corresponds to the axis crossing angle ψ, and is configured to be able to rotate, for example, about ± 20 °. When the rotation angle is 0 ° in the reference state, ψ = 0 °, and the axis of the work gear 14 coincides with the X direction.

  The head stock 214 includes one of a sub-slider 230 in the X direction, a shaft support box 232 that can slide in the X direction with respect to the sub-slider 230, a stock motor 234 that drives the shaft support box 232, and one of the work gears 14. And a support shaft 236 that supports this side. The support shaft 236 corresponds to the axis J1. Since the tail stock 216 basically has a symmetrical configuration with respect to the head stock 214, the same reference numerals as those of the tail stock 216 are used and detailed description thereof is omitted. The head stock 214 and the tail stock 216 have different driving forces that move in the X direction. The head stock 214 has a larger driving force, and the head stock 214 defines the position of the work gear 14 in the X direction. The head stock 214 and the tail stock 216 approach and separate when the work gear 14 is attached and detached. The head stock 214 and the tail stock 216 are not provided with a drive source for rotating the work gear 14.

  The roller cutter unit 220 includes two roller cutters 228 arranged in parallel in the X direction, a roller cutter support base 240 that rotatably supports these roller cutters 228, a Y slide base 242, and a Y motor 244. The Y motor 244 advances and retracts the roller cutter support base 240 in the short direction of the X slide base 210 with respect to the Y slide base 242 (in the Y direction when ψ = 0, hereinafter simply referred to as the Y direction). Let The distance between the two roller cutters 228 is adjusted to match the tooth width of the work gear 14, and the flash can be removed by being applied to the work gear 14. The roller cutter unit 220 is not provided with a drive source for rotating the roller cutter 228, and the roller cutter 228 contacts the work gear 14 and removes the flash while rotating. The roller cutter unit 220 is provided on the slide base 210.

  Next, the tool support unit 208 includes a Z slide base 250, a tool support mechanism box 252 that moves up and down in the Z direction with respect to the Z slide base 250, and a turret mechanism 254 that rotates intermittently with respect to the tool support mechanism box 252. Have

  The Z slide base 250 is provided adjacent to the drive panel 206 and extends in the Z direction, and holds the tool support mechanism box 252 so as to be movable up and down in the Z direction. A Z motor 256 that raises and lowers the tool support mechanism box 252 is provided on the Z slide base 250.

  The tool support mechanism box 252 includes an index motor 258 that intermittently rotates the turret mechanism 254 every 60 ° and a spindle motor 260, and has a considerable weight. The tool support mechanism box 252 further includes a positioning pin mechanism and a clutch mechanism (not shown). The turret mechanism 254 can be accurately positioned by the positioning pin mechanism. Power transmission to the turret mechanism 254 can be controlled by the clutch mechanism.

  The turret mechanism 254 is hexagonal when viewed from the side, and rotates every 60 ° in the YZ plane under the action of the index motor 258. In the vicinity of each hexagonal apex of the turret mechanism 254, a first arm 262a, a second arm 262b, a third arm 262c, a fourth arm 262d, a fifth arm 262e, and a sixth arm 262f are respectively directed in the X direction. Is provided. Various tools such as the phrasing cutter 18 can be attached to and detached from these arms 262a to 262f.

  The turret mechanism 254 is configured such that the lowermost one of the six arms 262 a to 262 f is arranged just above the workpiece gear 14. The six arms 262a to 262f are arranged at equal intervals (60 °), and a tool provided on any one of the arms arranged below so as to face the work gear 14 passes through a predetermined clutch mechanism. It can be rotated by a spindle motor 260. The turret mechanism 254 is provided with a tooth surface detection sensor (not shown), and the tool can be automatically engaged with the work gear 14 based on a signal from the tooth surface detection sensor.

  The first arm (first process portion) 262a performs chamfering processing and first shaving processing on the work gear 14 by the composite cutter 100, and the support shaft 236 (axis J1) of the workpiece support portion 204 is used. Since the axis crossing angle ψ is obtained by turning the rotary table 202, the processing section 12 (see FIG. 5) is formed by the first arm 262a and the support shaft 236.

  When chamfering is performed by the first arm 262a, the two roller cutters 228 are pressed against both ends of the work gear 14 under the action of the Y motor 244 to remove the flash at both ends. Can do. That is, the turret mechanism 254 and the roller cutter unit 220 can approach the work gear 14 from different directions (Z direction and Y direction), respectively, and perform chamfering and deburring simultaneously. The processing time can be shortened. After deburring, the roller cutter 228 is returned to its original position.

  The third arm (second process part) 262 c performs the second shaving process on the work gear 14, and the fifth arm (third process part) 262 e is 3 for the work gear 14. This is the second shaving process. The third arm 262c is provided with a shaving cutter 112 for precision finishing, and the fifth arm 262e is provided with a shaving cutter 114 for more precise finishing. The second arm 262b, the fourth arm 262d, and the sixth arm 262f are spares. Thus, when three tools are used, the balance of the turret mechanism 254 is improved by providing every other spare. When using two tools, it is good to provide a tool in the position which opposes, and make others the reserve.

  By the rotation of the turret mechanism 254, the first arm 262a, the third arm 262c, and the fifth arm 262e are sequentially moved to positions facing the work gear 14 of the work support unit 204, and the work gear 14 can be machined. . In other words, each tool of the turret mechanism 254 can be moved up and down under the action of the Z motor 256, so when chamfering the work gear 14, it is lowered and meshed with the work gear 14 to rotate the turret mechanism 254. Ascend and evacuate.

  When machining the work gear 14, the work gear 14 rotates along with the engagement of the tool of the turret mechanism 254. Therefore, a drive source for rotating the work gear 14 is not required, and the configuration is simple. Since each tool connected to the turret mechanism 254 is larger than the work gear 14, the inertia is large, and the spindle motor 260 is necessarily large to some extent. By using such a large spindle motor 260, the time for accelerating / decelerating the work gear 14 through a tool can be shortened. In other words, since the work gear 14 has relatively small inertia, it easily follows the tool and accelerates or decelerates, and the machining time can be shortened.

  In the gear machining apparatus 10b, hydraulic driving, pneumatic driving, and electric driving are properly used according to the driving location. The axes of the X motor 219, the base rotation motor 222, the Y motor 244, and the Z motor 256 are precisely positioned by NC control.

  When machining the work gear 14, the weights of the tool support mechanism box 252 and the turret mechanism 254 are added to the work gear 14. The weights of the tool support mechanism box 252 and the turret mechanism 254 have a considerable weight, and even if the Z motor 256 does not generate an excessively large force (for example, the current of the Z motor 256 is 0). Even) a sufficient load can be efficiently applied to the work gear 14. As a result, machining can be performed while the workpiece gear 14 is being pressed appropriately, and the workpiece gear 14 can be prevented from being shaken or decentered during machining, and stable machining can be performed.

  According to the gear processing device 10b configured as described above, in one device, the first arm 262a performs chamfering processing and the first shaving processing by the composite cutter 100, and the second arm 262b and the third arm 262c. Further tooth surface processing by the shaving cutters 112 and 114 can be performed, which is efficient. Further, since the composite cutter 100 meshes with the work gear 14 with an axis crossing angle ψ, not only chamfering is performed on the end face corner portions 30 and 31 of the work gear 14 but also crushing is caused. The occurrence of meat swell can be suppressed.

  Furthermore, since the workpiece support unit 204 is provided on the rotary table 202 that adjusts the orientation with respect to the arms 262a to 262f, an appropriate axis crossing angle ψ according to the work gear 14 can be set. .

  The rotation axis of the turret mechanism 254 is in a state having an axis crossing angle ψ with respect to the axis J2 of the workpiece support portion. That is, since the turret mechanism 254 itself is relatively inclined with respect to the axis J2, both the composite cutter 100 and the shaving cutters 112 and 114 mesh with the work gear 14 with an axis crossing angle ψ. The individual angle adjustment is not necessary, and the configuration is simple.

  According to the turret mechanism 254, one gear processing apparatus 10b can perform chamfering processing and shaving processing with the composite cutter 100 and further processing of tooth surfaces with the shaving cutters 112 and 114, which is efficient. Further, since the shaving process is performed separately for the first arm 262a, the third arm 262c, and the fifth arm 262e, the first process part by the first arm 262a is roughly finished, and the second process part by the third arm 262c is precision. Finishing, the third process part by the fifth arm 262e can be used as a more precise finish, and appropriate tools can be used properly.

  In the gear machining apparatus 10 b, various tooth surfaces can be formed on the work gear 14 by the simultaneous and coordinated operation of the X motor 219 and the Z motor 256.

  In addition, the work gear 14 can process the tooth surface 28 to a considerably high degree by the shaving cutter portion 42 of the composite cutter 100 of the first arm 262a, and depending on the design conditions (tact time, etc.) Processing of one or both of the five arms 262e may be omitted.

  As described above, according to the gear machining apparatuses 10a and 10b according to the present embodiment, the teeth of the work gear 14 are obtained by engaging the phrasing cutter portions 40a and 40b with the work gear 14 with the axis crossing angle ψ. While chamfering the end face corner portions 30 and 31 of the surface 28, the occurrence of the raised portion 80 can be suppressed. Even if the raised portion 80 is generated, the raised portion 80 can be cut and removed by the shaving cutter portion 42.

  Furthermore, the chamfering process and the shaving process can be performed at the same time, and the subsequent shaving process of the second process can be omitted or the time can be shortened, which is efficient. Conventionally, the time for a single shaving process is long, and this tends to increase the tact time. However, the shaving process as the second process can be omitted or the time can be shortened, and the tact time can be shortened. Figured.

  In general, the shaving process takes more time than the chamfering process by the phrasing cutter. However, the shaving process is performed by dividing the shaving process into the first process and the second process (or the first process to the N-th process (N ≧ 3)). One process time can be shortened. Moreover, the tact time can be shortened by setting the first step and the second step (or the first step to the N-th step) at substantially the same time.

  Since the occurrence of the raised portion 80 can be prevented by chamfering using the composite cutter 100, for example, a highly accurate gear can be obtained even if tooth grinding is omitted. Even if tooth grinding is omitted, gears with higher accuracy can be obtained by gear honing. In this case, since the raised portion 80 does not substantially exist in the work gear 14, the influence of the subsequent gear machining (for example, shaving machining, tooth grinding machining, gear honing machining) on the tool is considerably suppressed. Can do.

  The gears obtained by the gear machining apparatuses 10a and 10b according to the present embodiment have high hardness through heat treatment, and are suitable for high-accuracy vehicle transmissions that require high output, quietness, and durability. is there.

  On the other hand, even for gears that are not relatively high in accuracy and are not subjected to heat treatment, the chamfering by the gear machining apparatuses 10a and 10b hardly generates a raised portion, so that the load on the tool in tooth surface finishing such as shaving to be performed next. Is small, and the tool life can be extended. Thereby, while reducing the frequency | count of stopping a machine tool for a tool change operation | work, the frequency | count of a maintenance and inspection, tool expense can be suppressed.

  Of course, the gear machining apparatuses 10a and 10b are effective even when heat treatment is performed with a gear having relatively low required accuracy and the tooth surface finish is not performed thereafter.

  The gear machining device according to the present invention is not limited to the above-described embodiment, and various configurations can be adopted without departing from the gist of the present invention.

It is a perspective view of a work gear. It is a perspective view of a composite cutter. It is a cross-sectional front view of a composite cutter. It is a disassembled perspective view of a composite cutter. It is a schematic perspective view of a process part. It is the schematic diagram which each developed the to-be-cut gear and the phrasing cutter part along the surrounding surface. It is the schematic diagram which each developed the to-be-cut gear and the phrasing cutter along the surrounding surface in the meshing state which concerns on a prior art. FIG. 8A is a schematic perspective view of the meshing portion at the initial stage of meshing, FIG. 8B is a schematic perspective view of the meshing portion at the middle stage of meshing, and FIG. 8C is a schematic perspective view of the meshing portion at the final stage of meshing. It is a schematic perspective view of the right tooth surface after a process. FIG. 10A is a diagram showing the movement trajectory of the tooth surface of the phrasing cutter at the end face corner when the axis crossing angle is 5 °, and FIG. 10B is the phrasing cutter at the end face corner when the axis crossing angle is 8 °. It is a figure which shows the movement locus | trajectory of this tooth surface. It is a schematic perspective view of the left tooth surface after a process. It is the schematic diagram which expanded a part of workpiece gear and a phrasing cutter part along the surrounding surface, respectively. It is an enlarged side view of the meshing part of a phrasing cutter part and a to-be-cut gear. It is an enlarged view of the end face corner portion of a work gear machined with an axis crossing angle of 0 °. It is an enlarged view of the end face corner part of the to-be-cut gear processed by setting an axis crossing angle as 5 degrees. It is an enlarged view of the end face corner part of the to-be-cut gear processed by making an axis crossing angle into 8 degrees. It is an enlarged view of the end face corner portion of the 2000th workpiece gear when the axis crossing angle is 5 ° and machining is performed 2000 times. It is a schematic diagram which shows the relationship between the tooth | gear in a phrasing cutter, an axis crossing angle, a cutter tooth tip width | variety, interference amount, a clearance gap, and a cutter remaining width. FIG. 19A is a diagram showing the movement trajectory of the tooth surface of the phrasing cutter at the end face corner when the axis crossing angle is 4 °, and FIG. 19B is the phrasing cutter at the end face corner when the axis crossing angle is 5 °. FIG. 19C is a diagram showing the movement trajectory of the tooth surface of the phrasing cutter at the end face corner when the axis crossing angle is 6 °. It is a top view of the gear processing apparatus concerning a 1st embodiment. It is a perspective view of the gear processing apparatus which concerns on 2nd Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10a, 10b ... Gear processing apparatus 12 ... Processing part 14 ... Work gear 26 ... Teeth 28 ... Tooth surface 30, 31 ... End face corner part 32a, 32b ... Processing tooth 80 ... Swelling part 101 ... Table 102 ... 1st stage (1st stage) (1 process part)
104 ... 2nd stage (2nd process part) 106 ... 3rd stage (3rd process part)
108 ... Loading / unloading stage 110a-110d ... Rotating shaft (work support part)
112, 114 ... shaving cutter 202 ... turntable (turntable)
204 ... Work support unit 220 ... Roller cutter unit 224 ... Sensor 228 ... Roller cutter 234 ... Stock motor 236 ... Support shaft 252 ... Tool support mechanism box 254 ... Turret mechanism 262a to 262f ... Arm J1 ... Axis J2 ... Axis ψ ... Axis crossing Corner

Claims (11)

A workpiece support that pivotally supports the work gear,
A cutter support portion that pivotally supports the composite cutter so as to mesh with the work gear provided on the workpiece support portion;
The cutter support portion meshes the phrasing cutter with the work gear with an axis crossing angle ψ,
The composite cutter has a phrasing cutter part and a shaving cutter part,
The phrasing cutter part and the shaving cutter part have an arc part having a plurality of processing teeth, and are overlapped to form a disk shape,
Each of the arcing portions of the phrasing cutter portion and the shaving cutter portion is disposed coaxially. The gear machining apparatus according to claim 1,
It has a first process part and a second process part that move relative to the work support part and sequentially process it,
The cutter support part and the composite cutter are provided in the first process part,
The gear processing apparatus, wherein the second process unit includes a shaving cutter that processes a tooth surface of the gear to be cut. The gear machining apparatus according to claim 1 or 2,
The gear machining apparatus, wherein the work support portion is provided on a turntable that adjusts a direction with respect to the first process portion. The gear processing device according to any one of claims 1 to 3,
The gear to be machined is a helical gear.
A gear machining device. The gear machining apparatus according to claim 4, wherein
The gear machining apparatus, wherein the work gear is a gear of a vehicle transmission. The gear machining apparatus according to claim 1,
The composite cutter and the shaving cutter are provided in a turret mechanism, and move to a position facing the workpiece support portion in order by the rotation of the turret mechanism to process the gear to be cut. The gear machining apparatus according to claim 6, wherein
The work support portion is provided below the turret mechanism, and the turret mechanism is lowered so that the phrasing cutter and the shaving cutter are engaged with the work gear. The gear machining apparatus according to claim 6 or 7,
The gear machining apparatus according to claim 1, wherein the rotation shaft of the turret mechanism has an axis crossing angle ψ with respect to the axis of the workpiece support portion. In the gear processing apparatus according to any one of claims 1 to 8,
A gear machining apparatus characterized by matching a distance between axes of a shaving cutter unit and a phrasing cutter unit and a work gear. In the gear processing apparatus according to any one of claims 1 to 9,
The gear supporting device is characterized in that the work supporting portion does not have a rotational drive source of the work gear, and the work gear meshes with the composite cutter and rotates together. In the gear machining apparatus according to any one of claims 1 to 10,
A gear machining apparatus, comprising: a roller cutter unit that deburres the workpiece gear by bringing two roller cutters into contact with each other from a direction different from the cutter support portion.

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