JP4538074B2 - Gear machining method - Google Patents

Description

  The present invention relates to a gear machining method for machining a workpiece gear in a plurality of machining steps by sequentially using a plurality of cutters that are driven independently.

  In general, gear machining includes rough cutting with a hob, chamfering, tooth surface shaping with a shaving cutter, carburization and quenching by heat treatment, and gear grinding and gear honing to improve accuracy.

  In such gear machining, it is necessary to perform meshing alignment between the work gear as a workpiece and the machining tool at the start of machining. Control of the meshing position between the work gear and the processing tool is a relatively time-consuming process, and in particular, when performing a plurality of processing processes as described above, the work gear and The meshing position with the processing tool is required.

  In Patent Document 1, the present applicant has proposed a gear meshing method for meshing a work gear and a machining tool. According to this method, the engagement time can be shortened by performing the engagement control by a mechanism using an encoder, a sensor, or the like.

Japanese Patent Laid-Open No. 7-148617

  By the way, when machining the work gear in a plurality of machining processes as described above, usually, the predetermined meshing control is repeated for each process, but it is necessary to perform setting from one for each machining process. Tends to take time.

  The present invention has been made in connection with such a conventional technique, and even when a work gear is machined in a plurality of machining steps, the work gear and the work tool are efficiently meshed in a short time. It is an object of the present invention to provide a gear machining method that can improve production efficiency.

  The gear machining method according to the present invention has the following characteristics.

  First feature: A gear machining method according to the present invention is a gear machining method for machining a work gear in a plurality of machining steps by sequentially using a plurality of cutters that are independently driven, A first machining step, which is supported by a self-supporting drive and meshes the machining teeth of the first cutter with the teeth of the work gear, and machining the teeth, and after the first machining step, the first machining Using the setting data between the machined teeth in the process and the teeth, a meshing process of meshing the machined teeth of the second cutter and the teeth of the work gear, and after the meshing process, And a second machining step of machining the teeth of the work gear with a second cutter.

  According to such a method, the next second machining step is performed using the setting data (meshing position information) between the machining teeth of the first cutter and the teeth of the workpiece gear used in the first machining step. A meshing step of meshing the processing teeth of the second cutter and the teeth of the work gear used in the above. Therefore, by effectively utilizing the setting data of the first cutter and the work gear that are already meshed, the second cutter and the work gear can be meshed smoothly and in a short time, and the production efficiency can be improved. Can be improved.

  Second feature: In the meshing step, after the first processing step, the first cutter is rotated by a predetermined angle based on a preset reference position of the first cutter, and the first process is performed. After matching the engagement reference point of the cutting teeth of the cutter with the most advanced position in the cutting direction, the first cutter is retracted and replaced with the second cutter, so that the engagement of the second cutter is smooth. Since it can be performed, it is preferable.

  Third feature: In the meshing step, the second cutter is further rotated by a predetermined angle based on a reference position preset for the replaced second cutter, and the second cutter is processed. After the tooth engagement reference point is made to coincide with the most advanced position in the cutting direction, the second cutter is advanced and meshed with the work gear, so that the second cutter meshes more smoothly. be able to.

  Fourth feature: The reference position may be a keyway.

  Fifth feature: the meshing reference point may be the tip center or the root center of the processed tooth.

  Sixth feature: When the drive device for driving the cutter independently has a drive control mechanism, the cutter and the work gear can be easily engaged with each other.

  Seventh feature: the drive control mechanism may be a servo mechanism.

  Eighth feature: In the meshing step, after the first machining step is finished, the support shaft that pivotally supports the workpiece gear by the non-self-supporting drive is removed from the workpiece gear, thereby elastically supporting the column. The cutting gear is placed on the cassette and the first cutter is replaced with the second cutter, and then the second cutter and the cutting gear placed on the cassette are engaged. In other words, since the work gear can move somewhat, the second cutter can be engaged more smoothly.

  Ninth feature: In the first machining step, a gear attaching / detaching device having a cassette on which a work gear is placed and a support column elastically supporting the cassette is used, and the work gear is placed on the cassette. In this state, when the first cutter and the work gear are in rolling contact with each other by being sent to the meshing position with the first cutter rotated at a lower speed than during machining, the first and the second gears are smoothly and reliably engaged. 1 cutter and a to-be-cut gear can be meshed.

  According to this method, the setting data between the tooth of the first cutter used in the first machining step and the tooth of the gear to be cut is used, and the second cutter used in the next second machining step is used. It has a meshing step of meshing the machining teeth with the teeth of the work gear. Therefore, the second cutter and the work gear can be meshed smoothly and in a short time by effectively using the setting data of the first cutter and the work gear already meshed.

It is a perspective view which shows an example of the to-be-cut gear processed with the gear processing method which concerns on this Embodiment. It is a partially omitted perspective view of a chamfered portion. It is the schematic diagram which each developed the to-be-cut gear and the phrasing cutter along the surrounding surface. It is a partially-omission perspective view of a shaving process part. FIG. 3 is a schematic view in which a work gear and a shaving cutter are engaged with each other and developed along a circumferential surface on a pitch cylinder. It is a perspective view which shows an example of the gear processing apparatus which enforces the gear processing method which concerns on this Embodiment. 7A is an explanatory view showing a state before the work gear is pivotally supported by the support shaft of the gear machining apparatus shown in FIG. 6, and FIG. 7B shows that the work gear is pivoted by the support shaft from the state shown in FIG. 7A. It is explanatory drawing which shows the state supported. It is explanatory drawing which shows the support shaft and gear holder complex which concern on the modification of the support shaft of the gear processing apparatus shown in FIG. It is a partially omitted perspective view of the gear attaching / detaching device. It is a disassembled perspective view of the cassette which comprises the gear attachment / detachment apparatus shown in FIG. It is a perspective view of the support | pillar and base which comprise the gear attachment / detachment apparatus shown in FIG. It is a partially omitted sectional view along the axial direction of the cassette and the support column. It is explanatory drawing which shows the state at the time of the process of the to-be-cut gear mounted in the cassette. 3 is a flowchart of a gear machining method according to the present embodiment. FIG. 15A is an explanatory view showing a state in which the work gear is conveyed to the machining unit by the gear attaching / detaching apparatus shown in FIG. 9, and FIG. 15B is a rolling mesh with the machining tool while the work gear is conveyed to the machining unit. FIG. 15C is an explanatory view showing a state where the work gear and the machining tool are completely meshed with each other. FIG. 16A is an explanatory view showing a state in which the work gear conveyed to the machining unit by the gear attaching / detaching device shown in FIG. 9 interferes with the machining tool at the time of rolling meshing, and the cassette is swung downward. FIG. 16B is an explanatory diagram showing a state in which the work gear and the machining tool are properly meshed with each other from the state shown in FIG. 16A. It is explanatory drawing which shows the relationship between the keyway which is an example of the reference position of a processing tool, and a processing tooth. FIG. 18A is an explanatory diagram showing a state in which the phase of the phrasing cutter that has been processed is phase-controlled by the gear meshing control method that is implemented as part of the gear processing method according to the present embodiment, and then pulled up, and FIG. FIG. 18 is an explanatory view showing a state in which the phrasing cutter is replaced with a shaving cutter and the phase control of the shaving cutter is performed, and FIG. 18C is an explanatory view showing a state in which the shaving cutter and the work gear are meshed with each other. It is. It is explanatory drawing which shows the other example of the phase control of the processing tool at the time of a tool exchange.

  Hereinafter, embodiments of the gear machining method according to the present invention will be described in detail with reference to the accompanying drawings.

  The gear machining method according to the present embodiment is, for example, a method of machining the workpiece gear in a plurality of machining steps including chamfering of the end face corner portion of the workpiece gear and shaving of the tooth surface. This gear machining method is implemented, for example, by a gear machining device 10 (see FIG. 6) equipped with a gear attachment / detachment device 11 that attaches / detaches a workpiece gear to / from a machining portion.

  Prior to the description of the gear machining method, the gear machining apparatus 10 will be described. First, the chamfering processing part 12 that processes the work gear 14 that is attached and detached by the gear attaching / detaching device 11 with a phrasing cutter, and the shaving processing part 13 that processes the work gear 14 that has been chamfered with a shaving cutter will be described.

  As shown in FIG. 1, the work gear 14 is, for example, a helical gear, and there are sharp portions 33 at the left and right end face corner portions 30 and 31 in a state where the gear is roughly cut from the material by a hob. Therefore, in the gear machining method according to the present embodiment, after chamfering the end face corners 30 and 31 by the chamfering part 12, the tooth surface 28 of the tooth 26 is cut by the shaving part 13.

  The work gear 14 to be machined by the gear machining method according to the present embodiment is not limited to a helical gear, and may be a spur gear or the like. The work gear 14 is, for example, a gear of a vehicle transmission. A gear machined by the gear machining method using the chamfering part 12 and the shaving part 13 is highly accurate, excellent in quietness and durability, and suitable for a vehicle transmission.

  FIG. 2 is a partially omitted perspective view of the chamfered portion 12.

  As shown in FIG. 2, the chamfering portion 12 includes a shaft J <b> 1 as a workpiece support portion that pivotally supports the workpiece gear 14, a phrasing cutter 18 that is a chamfering tool, and a cutter support portion that pivotally supports the phrasing cutter 18. As axis J2. 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 phrasing cutter 18.

  The phrasing cutter 18 includes a piece having a group of chamfering processing teeth 32 a on one side in the thickness direction and a piece having a group of chamfering processing teeth 32 b on the other side, and these are fixed to the boss 36. This is a so-called three-piece structure.

  The shaft J2 pivotally supports the phrasing cutter 18 so that the phrasing cutter 18 is engaged with the work gear 14 pivotally supported by the shaft J1. The axis J2 meshes the phrasing cutter 18 with the workpiece gear 14 with a non-zero axis crossing angle ψ1, and is provided at an angle at which the machining teeth 32a and 32b of the phrasing cutter 18 do not interfere with the tooth surface 28 of the workpiece gear 14. (See FIG. 3). The axis crossing angle ψ1 is an angle formed by the axis J1 of the work gear 14 and the axis J2 of the phrasing cutter 18 (see FIG. 3).

  FIG. 3 shows the relative positional relationship between the teeth 26 of the work gear 14 and the machining teeth 32a and 32b of the phrasing cutter 18, and each of the work gear 14 and the phrasing cutter 18 is disposed along the circumferential surface. It is the expanded schematic diagram.

  As shown in FIGS. 2 and 3, the machining teeth 32 a and the machining teeth 32 b are separated according to the thickness of the work gear 14, and the phrasing cutter 18 and the work gear 14 rotate while meshing with each other. As a result, one processing tooth 32a presses against one end face corner 30 to crush the chamfered portion 33 and chamfers, and the other processing tooth 32b presses against the other end face corner 31 to obtain a sharp portion. Crush 33 and chamfer.

  As apparent from FIG. 3, the work gear 14 and the phrasing cutter 18 have an axis crossing angle ψ 1 and intersect at an angle. Accordingly, when the phrasing cutter 18 is driven to rotate, the work gear 14 rotates in the right direction (arrow A1 direction) in FIG. 3, and the phrasing cutter 18 rotates in the oblique direction (arrow A2 direction) by an angle ψ1.

  As a result, the processed teeth 32a of the phrasing cutter 18 first mesh with the teeth 26 as shown by an arrow B1 in FIG. Subsequently, the processing teeth 32a mesh with each other as shown by an arrow B2 in FIG. Thereafter, the processed teeth 32a mesh with each other as shown by an arrow B3 in FIG. 3 and come into contact with the substantially bottom portion of the teeth 26, and the end face corners 30 can be chamfered over the entire length to eliminate the sharp portions 33. Naturally, the other end face corner portion 31 of the work gear 14 can be appropriately chamfered by the processing teeth 32b of the phrasing cutter 18 as in the case of the end face corner portion 30 described above.

  At this time, in the chamfered portion 12, the phrasing cutter 18 meshes with the work gear 14 with the axis crossing angle ψ1, so that the sharpened portion 33 is chamfered by crushing against the end face corner portions 30, 31 of the work gear 14. In addition, the sliding between the surfaces including the lateral movement component occurs. Thereby, generation | occurrence | production of the surplus swell in the location adjacent to a chamfering part among the tooth surfaces 28 can be prevented, or it can suppress. The axis crossing angle ψ1 may be set in the range of 5 ° to 8 °, for example.

  FIG. 4 is a partially omitted perspective view of the shaving portion 13.

  As shown in FIG. 4, the shaving processing unit 13 includes a shaft J <b> 1 as a work support unit that supports the work gear 14, a shaving cutter 20 that is a shaving tool, and a cutter support unit that supports the shaving cutter 20. As an axis J3. The axis J3 can be rotated by a drive source (not shown). The axis J <b> 1 is the same as or similar to that of the chamfered portion 12, and rotates with the work gear 14 meshing with the shaving cutter 20.

  FIG. 5 shows the relative positional relationship between the teeth 26 of the work gear 14 and the machining teeth 44 of the shaving cutter 20. The work gear 14 and the shaving cutter 20 are engaged with each other on the circumferential surface of the pitch cylinder. It is the schematic diagram developed along.

  As shown in FIGS. 4 and 5, a plurality of serrations 46 serving as cutting blades are provided on the tooth surface of each processing tooth 44 of the shaving cutter 20. 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.

  The shaft J3 pivotally supports the shaving cutter 20 so that the shaving cutter 20 is engaged with the work gear 14 provided on the shaft J1. The axis J3 meshes the shaving cutter 20 with the work gear 14 at a non-zero axis crossing angle ψ2 (see FIG. 5). The axis crossing angle ψ2 is an angle formed by the axis J1 of the work gear 14 and the axis J3 of the shaving cutter 20 (see FIG. 5), and even if it is the same angle as the above axis crossing angle ψ1 (see FIG. 3). The angle may be different, and depends on the type of the work gear 14, but may be set in the range of 4 ° to 20 °, for example.

  When the shaving cutter 20 is driven to rotate, the shaving cutter 20 rotates in the upward direction (arrow A3 direction) in FIG. 5, and the work gear 14 rotates in an oblique direction (arrow A1 direction) by an angle ψ2. As a result, the machining teeth 44 of the shaving cutter 20 and the teeth 26 of the work gear 14 relatively slide in the direction of the teeth of the teeth 26, and the tooth surface 28 is cut by the serrations 46. That is, the processing teeth 44 abut against the tooth surface 28 so as to rub in the lateral direction as indicated by the arrow C1 in FIG. 5, and the teeth 26 abut as indicated by the arrow C2 in FIG. As a result, the tooth surface 28 is formed with a predetermined accuracy by the serration 46. This cutting is for forming the tooth surface 28, and is classified as finish cutting, unlike rough cutting with a hob or the like.

  Next, the gear machining apparatus 10 having the chamfering part 12 and the shaving part 13 basically configured as described above will be described.

  As shown in FIG. 6, the gear machining apparatus 10 includes a rotary table 202 provided on a base table 200, a work support unit 204 provided on the rotary table 202, and a drive panel that comprehensively controls the entire apparatus. (Control unit) 206 and a tool support unit 208 provided adjacent to the drive panel 206, and the gear attaching / detaching device 11 is disposed on the rotary table 202. In the description of the gear machining apparatus 10, the transverse direction is the X direction, the depth direction is the Y direction, and the height direction is the Z direction. Further, in FIG. 6, illustrations of an operation panel, a lubrication device, a hydraulic power source, a coolant, and the like of the gear machining device 10 are omitted.

  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 in the longitudinal direction of the X slide base 210 under the action of the X motor 219 (in the X direction when ψ1 (ψ2) = 0, hereinafter simply referred to as the X direction). is there.

  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), more 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. 6). The rotation of the slide base 210 corresponds to the axis crossing angles ψ1, ψ2, and is configured to be able to rotate, for example, about ± 20 °. When the rotation angle is 0 ° in the reference state, ψ1 (ψ2) = 0 °, and the axis of the work gear 14 coincides with the X direction.

  The head stock 214 includes one of a sub-slider 230a in the X direction, a shaft support box 232a that can slide in the X direction with respect to the sub-slider 230a, a stock motor 234a that drives the shaft support box 232a, and one of the work gears 14. And a support shaft 236a that pivotally supports this side. The support shaft 236a corresponds to the axis J1. The tail stock 216 is basically symmetrical with respect to the head stock 214, and includes a sub-slider 230b in the X direction, a shaft support box 232b that can slide in the X direction with respect to the sub-slider 230b, and a shaft support box. It has the stock motor 234b which drives 232b, and the support shaft 236b which pivotally supports one side of the cut gear 14. The head stock 214 and the tail stock 216 are not provided with a drive source for rotating the work gear 14 and are so-called non-self-supporting drives.

  The head stock 214 and the tail stock 216 have different driving forces that move in the X direction. For example, 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 The head stock 214 and the tail stock 216 approach and separate when the work gear 14 is attached and detached.

  Accordingly, as shown in FIGS. 7A and 7B, the support shafts 236a and 236b approach and separate from each other as a pair of center shafts (centering shafts) for supporting the work gear 14 so that the work gear 14 is moved to its axis. It is supported in the direction of the heart.

  In this case, holders 237a and 237b that can be engaged with and separated from each other are provided at the tips of the support shafts 236a and 236b facing each other. A protrusion shaft 238a is provided at the tip of one holder 237a, and an engagement recess 238b for engaging the protrusion shaft 238a is provided at the tip of the other holder 237b (see FIG. 7A). Therefore, the projecting shaft 238a is inserted through the through hole 14a of the shaft center of the work gear 14 and engaged with the engagement recess 238b, so that the holders 237a and 237b are integrally coupled, and the work gear 14 is attached to its shaft. It can be supported smoothly and quickly in the center direction. The through-hole 14a and the protruding shaft 238a may be provided with axial serration grooves (not shown) that can be engaged with each other.

  As shown in FIG. 8, holders 237 a and 237 b are integrally assembled in advance with respect to each work gear 14 that is sequentially processed by the gear processing apparatus 10 to form a gear holder complex 15. The body 15 may be transported and positioned by the gear attaching / detaching device 11 and supported by the pair of support shafts 236a and 236b. In this case, for example, on the back side of the holders 237a and 237b, engaging recesses 241a and 241b with which substantially truncated cone-shaped protrusions 239a and 239b formed at the tips of the support shafts 236a and 236b can be engaged, respectively. It is good to have it. In this configuration, since the work gear 14 is in the state of the gear holder complex 15 in advance, for example, the workability of the work gear when transported and stored in each process including the gear machining apparatus 10 is achieved. Can be improved. Further, the pair of support shafts 236a and 236b do not need to allow the protruding shaft 238a (see FIG. 7A) to be inserted through the through hole 14a of the shaft center of the work gear 14 when the work gear 14 is supported. The work gear 14 can be supported more smoothly and easily.

  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 has the roller cutter support 240 in the Y direction when the roller cutter support 240 is in the short direction of the X slide base 210 (ψ1 (ψ2) = 0). ). 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 that is a servo motor capable of servo control, 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 and the shaving cutter 20 can be attached to and detached from these arms 262a to 262f. The arms 262a to 262f correspond to the axis J2 (see FIG. 2) and the axis J3 (see FIG. 4).

  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 tool provided on the turret mechanism 254 and the work gear 14 can be engaged very easily by using a gear engagement control method described later.

  The first arm 262 a chamfers the work gear 14 with the phrasing cutter 18, and the support shafts 236 a and 236 b (axis J 1) of the workpiece support unit 204 are rotated at the axis crossing angle by the rotation of the rotary table 202. Since it has (psi) 1, the chamfering process part 12 (refer FIG. 2) is comprised by the 1st arm 262a and support shaft 236a, 236b.

  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. Processing time can be shortened. After deburring, the roller cutter 228 is returned to its original position.

  The third arm 262c performs the first shaving process (first shaving process) on the work gear 14, and the fifth arm 262e performs the second shaving process (first shaving process on the work gear 14). 2 shaving process). Here, since the support shafts 236a and 236b (axis J1) of the workpiece support unit 204 have the axis crossing angle ψ2 due to the turning of the rotary table 202, the third arm 262c (fifth arm 262e) and the support shafts 236a and 236b. The shaving process part 13 (refer FIG. 4) is comprised. That is, the shaving cutter 20 for rough finishing is provided on the third arm 262c, and the shaving cutter 20 for precision finishing is provided on the fifth arm 262e. The shaving cutters 20 for rough finishing and precision finishing may be the same or different suitable for each process.

  The second arm 262b, the fourth arm 262d, and the sixth arm 262f are spares. For example, the above-mentioned spares for the phrasing cutter 18 and the shaving cutter 20 can be provided, or a hob for gear cutting is provided. It can also be left.

  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.

  In the chamfering processing section 12 and the shaving processing section 13 configured as described above, the work gear 14 that is pivotally supported by the support shafts 236a and 236b is conveyed and carried out by the gear attaching / detaching device 11, and the phrasing cutter 18 and the like. And a position where it can be smoothly supported by the support shafts 236a and 236b.

  Next, the gear attaching / detaching device 11 will be described.

  As shown in FIGS. 9 to 12, the gear attaching / detaching device 11 includes a cassette 302 having a tooth mounting portion 300 on which the work gear 14 is placed and held in a free state in the rotation direction, and the cassette 302 is shaken. The column 304 includes a support column 304 that is elastically supported to be movable, a slider 306 to which the column is fixed, and a base 310 having a pair of guide rails (slider receiving portions) 308 that support the slider 306 so as to advance and retreat.

  Hereinafter, the direction in which the gear attaching / detaching device 11 is mounted on the gear machining device 10 is used as a reference, and the transverse direction is defined as the X direction, the depth direction is defined as the Y direction, and the height direction is defined as the Z direction (see FIG. 6). . In this case, the gear attaching / detaching device 11 has the base 310 fixed to the X slide base 210 on the rotary table 202 of the gear machining device 10, and at this time, the advancing / retreating direction of the slider 306 is the short direction of the X slide base 210 ( When ψ1 (ψ2) = 0, the direction is the Y direction (hereinafter, also simply referred to as the Y direction). The gear attaching / detaching device 11 can be suitably used even if it is a device other than the gear machining device 10.

  As shown in FIG. 10, the cassette 302 is provided with a support body 312 that is elastically supported so as to be swingable with respect to the support column 304, and the tooth mounting unit 300, and is detachably fixed to the support body 312. And a table 314.

  The support 312 includes a narrow portion 320 provided with a through-hole 318 in the X direction through which a shaft 316 (see FIG. 11) serving as a swing axis of the cassette 302 with respect to the support column 304 is inserted, and a Y portion from below the narrow portion 320. A spring support bar 324 that protrudes in the direction and is inserted into a coil spring (elastic member) 322 (see FIG. 11), a trapezoidal groove (engagement groove) 326 that extends in the vertical direction (Z direction), and a spring support bar 324. And a stopper 328 projecting in the Y direction from below.

  The mounting table 314 includes a tooth mounting unit 300 on which the work gear 14 is mounted, and a trapezoidal convex portion (engaging convex portion) 330 that engages with the trapezoidal groove 326 in the Z direction. The tooth mounting part 300 is a semicircular groove part into which approximately half of the work gear 14 can be inserted. The pair of side walls 332 constituting the tooth mounting unit 300 has a substantially semicircular shape that serves as a relief when the support shafts 236a and 236b (see FIG. 7A) of the gear machining apparatus 10 pivotally support the workpiece gear 14. A notch 334 and a notch 336 reaching the substantially center bottom of the mounting surface 300a on which the work gear 14 is seated are formed. Each of the pair of left and right cutouts 336 is provided with a tapered surface 336a inclined outward. An arcuate cutout 338 is formed on the distal end side of the side wall 332 and is cut off shorter than the substantially semicircular mounting surface 300a. The distance between the pair of side walls 332 may be set to be slightly larger than the dimension in the thickness direction of the work gear 14.

  Therefore, as shown in FIGS. 9 and 10, the mounting table 314 is engaged with the support body 312 when the trapezoidal convex portion 330 is engaged with the trapezoidal groove 326. At this time, a set screw 342 is screwed into the screw hole 340 on the support 312 side, and is engaged with a stop recess 344 formed in a notch substantially at the center of the trapezoidal protrusion 330, so that the mounting table 314 is supported by the support 314. It is securely fixed to 312 in an easily removable state.

  As shown in FIG. 12, it is preferable that the mounting surface 300a constituting the tooth mounting unit 300 has a slightly flat semicircular shape with a changed radius in order to stably hold the work gear 14. . That is, in the tooth on-vehicle placement unit 300 (see FIG. 10) that is a substantially semicircular groove formed by the side wall 332 and the placement surface 300a, the radius r2 of the opening on the insertion side of the work gear 14 is set to the work gear. 14 is larger than the radius r1 on the bottom side on which the seat 14 is seated (r2> r1), and the radius r1 is the same as the outer radius of the work gear 14 to be placed (slightly larger diameter than the work gear 14). And small diameters). Thus, when the opening side is set to a radius r2 having a slightly larger diameter, it is possible to more easily place and take out the work gear 14 on the tooth mounting unit 300 by manpower or a robot (not shown). .

  As shown in FIG. 11, the column 304 is fixed on the slider 306 with a bolt (not shown) and can move forward and backward together with the slider 306. The column 304 penetrates between the rectangular groove 346 extending in the vertical direction (Y direction) into which the narrow portion 320 of the support 312 and the stopper 328 constituting the cassette 302 are inserted, and the upper wall of the rectangular groove 346 in the X direction. A pair of fitting holes 348 that are recessed in a substantially central back surface of the rectangular groove 346, and a coil spring 322 is seated, and a circular recess 350 serving as a relief portion of the spring support bar 324 of the support 312 is provided. The slider 306 may be configured in a block shape, for example, and may have a through hole (not shown) through which the guide rail 308 is inserted, and a wheel or the like (not shown) may be provided on the lower surface or side surface. The guide rail 308 which is a slider receiving portion is a cylindrical shaft, but may be a rail having another shape.

  Accordingly, as shown in FIGS. 9 and 12, the cassette 302 to which the support 312 and the mounting table 314 are fixed has the narrow width portion 320 and the stopper 328 inserted into the rectangular groove 346 of the column 304, and the circular recess portion. With the spring support bar 324 inserted into the coil spring 322 seated on 350, the shaft 316 is fitted from one fitting hole 348 through the through hole 318 to the other fitting hole 348.

  As a result, the cassette 302 is elastically supported by the coil spring 322, which is a compression spring, while being supported on the upper fulcrum with the shaft 316 as the swing axis, and the cassette 302 is supported by the arrows θ1 and θ2 in FIG. It can swing elastically in the direction (see the two-dot chain line in FIG. 12). In addition to the above-described upper fulcrum support, the cassette 302 can also be configured as a lower fulcrum support in which the shaft 316 is disposed below the coil spring 322, and the coil spring 322 can be configured as a tension spring instead of a compression spring.

  At this time, the rectangular groove 346 at a position corresponding to the stopper 328 is closed by the stopper plate 349, and stopper bolts 351 and 353 facing the stopper plate 349 and the stopper 328, respectively, are fixed. The stopper bolts 351 and 353 are basically set so that the cassette 302 is in contact with each other in a state of being perpendicular to the support (horizontal position, Y direction) (solid line position in FIG. 12). Accordingly, the cassette 302 can swing downward (in the direction of the arrow θ2 in FIG. 12) until the stopper 328 contacts the rectangular groove 346, while the stopper bolts 351 and 353 are at the horizontal position, which is the origin position. Since it abuts, swinging upward (in the direction of arrow θ1 in FIG. 12) is restricted. That is, for example, even when the cassette 302 is swung downward due to the contact between the work gear 14 and the tool, the cassette 302 is prevented from swinging upward from the horizontal position due to rebound due to the elastic force of the coil spring 322. Therefore, excessive contact or shocking contact between the work gear 14 and the tool can be prevented.

  As shown in FIGS. 9 and 11, the base 310 has four side walls 352 standing around it, and houses a slider 306 inside thereof, and a column 304 fixed on the slider 306 has side walls. Projecting upward from 352. An elongated hole 354 that is slightly shorter than the guide rail 308 is formed in a predetermined one (or two) of the side walls 352 aligned with the guide rail 308. Therefore, by inserting the set screw 356 into the elongated hole 354 and tightening and loosening the screw hole 358 on the side of the slider 306, the slider 306 can be moved along the guide rail 308 and fixed at a predetermined position. . The slider 306 is manually operated in this manner. For example, the slider 306 is moved forward and backward and locked by a lever means (not shown), or a predetermined operation button is pressed to a predetermined position via a motor (not shown). It can also be configured to be advanced / retracted and locked.

  The gear attaching / detaching device 11 as described above is a simple and low-cost semi-automatic attaching / detaching loader without specially providing a holding means such as a clamping means or a handling device for performing fine control, and the work gear 14 Can be easily placed and held on the tooth mounting portion 300, and the placed work gear 14 can be easily moved back and forth to a desired position by the slider 306 and positioned. Can be easily attached to and detached from the processing portion. For this reason, the loss time by attachment / detachment of the work gear 14 before and after processing can be reduced as much as possible.

  As shown in FIG. 13, the gear attaching / detaching device 11 supports the workpiece gear 14 conveyed and positioned between the head stock 214 and the tail stock 216 constituting the chamfering portion 12 or the like, that is, the workpiece support portion 204. The shafts 236 a and 236 b can be pivotally supported through the notch 334.

  At this time, the axes of the support shafts 236a and 236b are slightly higher in the vertical direction (Y direction) than the center point P1 (see FIG. 12) of the work gear 14 in the state of being placed on the placement surface 300a. Set. As a result, the work gear 14 pivotally supported by the support shafts 236a and 236b has its center point P2 (see FIG. 13) raised slightly above the center point P1 and is separated from the placement surface 300a. For this reason, the machining gear 14 does not interfere with the mounting surface 300a and the like during machining, and as a result, machining is performed while the cassette 302 is positioned at the machining portion without operating the slider 306 and the like. Thus, the machining can be started quickly and efficiently, and the work gear 14 after the machining can be carried out quickly. In addition, cutting oil, chips, and the like at the time of processing are effectively discharged to the outside by the notch 336 formed in the side wall 332 without accumulating on the mounting surface 300a.

  Since an arc-shaped notch 338 is provided at the front end side of the mounting table 314 constituting the cassette 302, for example, when the chamfering process is performed by the phrasing cutter 18, the roller cutter 228 does not interfere with the work gear 14. Can be set (see FIG. 13).

  Since the cassette 302 on which the work gear 14 is placed is elastically supported so as to be swingable with respect to the support column 304, when the work gear 14 and a tool (such as the phrasing cutter 18), which will be described later, mesh with each other, as necessary. The cassette 302 swings (see FIG. 16A). That is, at the time of meshing, even if the tooth tip of the tool that moves forward in the meshing direction (Y direction) and the tooth tip of the work gear 14 interfere with each other, the cassette gear 302 causes the work gear 14 to move. It is possible to escape in a direction away from the meshing direction. For this reason, breakage of the tool and the work gear 14 due to tooth tip interference can be prevented as much as possible, and the meshing position can be easily corrected.

  The cassette 302 can be easily separated and mounted on a support body 312 that is fixed and supported on the support column 304 and a mounting table 314 on which the work gear 14 is mounted. For this reason, even if the outer diameter or the like differs depending on the type of the work gear 14, it is only necessary to replace only the mounting table 314 with one suitable for the shape, and the versatility is high. Of course, the support body 312 and the mounting table 314 may be configured as an integral type that cannot be separated.

  According to the gear machining apparatus 10, the first arm 262 a, the third arm 262 c, and the fifth arm 262 e are sequentially moved to a position facing the work gear 14 of the workpiece support unit 204 by the rotation of the turret mechanism 254, and the above-described gears. The work gear 14 conveyed by the attachment / detachment device 11 and supported by the support shafts 236a and 236b can be continuously processed. That is, since each tool of the turret mechanism 254 can be lifted and lowered under the action of the Z motor 256, when the chamfering process or the shaving process of the work gear 14 is performed, the tool is lowered and meshed with the work gear 14 so that the turret mechanism When rotating 254, it rises and retreats.

  The support shafts 236a and 236b that support the work gear 14 have a simple configuration that is non-self-supporting, and the work gear 14 rotates together with the tool of the turret mechanism 254 when engaged. 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 10, hydraulic driving, pneumatic driving, and electric driving are properly used according to the driving location. The rotation angle (phase) of the spindle motor 260 including the X motor 219, the base rotation motor 222, the Y motor 244, the Z motor 256, and the servo motor is 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.

  Thus, in the gear machining apparatus 10 (turret mechanism 254), in one apparatus, the chamfering process is performed by the first arm 262a by the phrasing cutter 18, and the teeth by the shaving cutter 20 by the third arm 262c and the fifth arm 262e. The surface 28 can be shaved, which is efficient.

  Moreover, since the workpiece | work support part 204 is provided in the rotary table 202 which adjusts direction with respect to each arm 262a-262f, the appropriate axis crossing angle | corner (psi) 2 (psi2) according to the to-be-cut gear 14 is set. be able to. As a result, the arms 262a to 262f of the turret mechanism 254 are in a state having an axis crossing angle ψ1 (ψ2) with respect to the axis J1 of the workpiece support unit 204. That is, since the turret mechanism 254 itself is relatively inclined with respect to the axis J1, both the phrasing cutter 18 and the shaving cutter 20 are easily meshed with the work gear 14 with the axis crossing angle ψ1 (ψ2). be able to. Of course, when the axis crossing angle ψ1 and the axis crossing angle ψ2 are set to the same angle, individual angle adjustment for each processing step is unnecessary, and a simpler configuration can be obtained. Similarly, since the gear attaching / detaching device 11 is also provided on the rotary table 202 via the base 310, the gear attaching / detaching device 11 is directly provided to the axis crossing angles ψ1, ψ2 by the rotating table 202 without providing a rotating mechanism or the like. Therefore, the work gear 14 can be accurately attached to and detached from the chamfering portion 12 and the shaving portion 13.

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

  Next, the gear machining method according to the present embodiment will be described by exemplifying a case where it is carried out using the gear attaching / detaching device 11 and the gear machining device 10 on which the gear attaching / detaching device 11 is mounted.

  As shown in FIG. 14, in the gear machining method according to the present embodiment, first, in step S101, gear cutting is performed on the material by a hob or the like (tooth cutting step). By this gear cutting, a schematic shape of the teeth 26 of the work gear 14 is formed. In the case of the present embodiment, the gear cutting step is performed by a cutting machine or the like other than the gear machining apparatus 10, and the gear cutting apparatus 10 chamfers and shave the gear 14 to be cut. Needless to say, gear cutting may be performed by the gear machining apparatus 10.

  In step S102, the gear 14 to be cut cut in step S101 is conveyed and positioned by the gear attaching / detaching device 11 to the machining portion of the gear machining device 10 (gear carrying-in process).

  In such a gear carrying-in process in step S102, first, the work gear 14 is placed on the tooth mounting unit 300 of the cassette 302 by manpower, a robot, or the like (see FIG. 15A).

  Next, the slider 306 is moved forward, and the work gear 14 is conveyed and positioned forward in the cutting direction (Y direction) of the phrasing cutter 18 as a machining tool, that is, to the meshing standby position immediately below the phrasing cutter 18. 306 is fixed (see FIG. 15B).

  At this time, the phrasing cutter 18 is rotated in advance at a low speed that is sufficiently slower than the time of machining in a state where the framing cutter 18 is lowered to the machining position (meshing standby position). Then, the workpiece gear 14 is rotated by the processing teeth 32a and 32b of the phrasing cutter 18 being rotated at a low speed in the tooth mounting unit 300 whose rotation direction is held free during the movement to the meshing standby position. While being engaged, they gradually mesh (see FIG. 15B). That is, the work gear 14 is meshed with the phrasing cutter 18 while being rolled on the placement surface 300 a while being held in the tooth on-vehicle placement unit 300. In the meshing by such a rolling method, the phrasing cutter 18 and the work gear 14 are in a preliminary meshing state in which the tooth tip and the tooth bottom are slightly separated from each other in order to achieve smoother and more reliable meshing. (See FIG. 15B).

  Therefore, as shown in FIG. 15C, the rotation of the phrasing cutter 18 is stopped, and the support shafts 236a and 236b are brought close to each other from both sides of the work gear 14 (see FIG. 7A) to engage with the protruding shaft 238a at the tip. The recess 238b is engaged (see FIG. 7B). Therefore, as described above, the shaft centers of the support shafts 236a and 236b are disposed slightly above the center of the work gear 14 placed on the placement surface 300a (see FIGS. 12 and 13). The work gear 14 pivotally supported by the support shafts 236a and 236b is pulled upward and separated from the placement surface 300a, and at the same time, is completely engaged with the phrasing cutter 18 (see FIG. 15C).

  In such a gear carrying-in process, at the time of meshing by the rolling method described above (see FIGS. 15A and 15B), the tooth tip of the work gear 14 and the tooth tip of the phrasing cutter 18 depending on the mounting state of the work gear 14 and the like. May interfere with each other (see FIG. 16A).

  However, as described above, in the gear attaching / detaching device 11, the cassette 302 provided with the tooth mounting unit 300 on which the work gear 14 is placed is elastically supported so as to be swingable (see FIG. 12). Accordingly, the work gear 14 pressed by the phrasing cutter 18 is elastically swung in the direction of the arrow θ2 by the cassette 302 and retracted (see FIG. 16A). In addition, since the work gear 14 is held in the tooth mounting unit 300 in a free state, it slightly rotates when the coil spring 322 bounces in the direction of the arrow θ1 due to the elastic action of the coil spring 322 and is suitably meshed with the phrasing cutter 18. A preliminary meshing state similar to that shown in FIG. 15B is obtained (see FIG. 16B). At the time of rebounding, the cassette 302 abuts stopper bolts 351 and 353 (see FIG. 12) to restrict excessive swinging upward, and the work gear 14 and the phrasing cutter 18 are excessively contacted or shocked. Can be effectively prevented.

  When the tooth tips interfere with each other as shown in FIG. 16A, the slider 306 is moved slightly back and forth by manual operation or the like, thereby changing the phase of the work gear 14 and eliminating the interference state more quickly. A meshing state as shown in 16B is also possible.

  Next, in step S103, since the phrasing cutter 18 and the work gear 14 are engaged with each other in step S102, the chamfering process of the work gear 14 by the chamfering part 12 is performed (chamfering process).

  In the gear attaching / detaching device 11, as described above, the work gear 14 is completely separated from the placement surface 300a when the tool and the work gear 14 are completely meshed with each other (see FIGS. 13 and 15C). The step S103 can be started immediately while the cassette 302 and the like are kept waiting at the completion position of the step S102. Further, since the arc-shaped notch 338 is provided on the front end side of the cassette 302, the roller cutter 228 can be smoothly applied to the work gear 14 without interference with the cassette 302 during the chamfering process ( Deburring can be performed simultaneously with chamfering. At this time, cutting oil, chips, and the like at the time of processing flow down to the mounting surface 300a and the like, but do not collect on the mounting surface 300a, and the outside from the notch 336 and the tapered surface 336a formed on the side wall 332. Effectively discharged.

  In step S103, the chamfering section 12 chamfers the phrasing cutter 18 with the workpiece gear 14 having an axis crossing angle ψ1 as described above. For this reason, it is possible not only to crush and chamfer the end face corner portions 30 and 31 of the work gear 14 but also to suppress the occurrence of surging due to crushing. Easy and accurate.

  In step S104, the shaving process part 13 performs the first shaving process of the work gear 14 (first shaving process). In the shaving processing section 13, as described above, the shaving cutter 20 meshes with the work gear 14 with an axis crossing angle ψ2 to perform shaving, and the tooth surface is subjected to rough finish cutting until a predetermined allowance is obtained. Surface molding is performed.

  In step S104, for example, after the chamfering process in step S103 is completed, the support shafts 236a and 236b are detached from the work gear 14 so that the work gear 14 is in a free state in the tooth mounting unit 300 and the rotation is stopped. The phrasing cutter 18 is moved upward, the next shaving cutter 20 is indexed, and the shaving cutter 20 is engaged with the work gear 14. Of course, with the work gear 14 being pivotally supported without separating the support shafts 236a, 236b, the tool is changed and meshed with the next shaving cutter 20, or the meshing by the above rolling method is performed again. A method or the like is also possible. The details of such a gear meshing control method between the tool and the work gear at the time of tool change will be described later.

  In step S105, the shaving processing unit 13 performs the second shaving process of the work gear 14 (second shaving process). For the second shaving process, it is preferable to perform a shaving process substantially similar to the first shaving process described above, but since the second shaving process is a precision finish cutting, the cutter cutting speed and the like are the same as the first shaving process. Different settings may be used.

  This step S105 is also used in the first shaving process in which, for example, after the first shaving processing in step S104 is completed, the support shafts 236a and 236b are detached from the work gear 14 and the rotation is stopped via the turret mechanism 254. The shaving cutter 20 is moved upward, the next shaving cutter 20 is indexed, and the shaving cutter 20 is meshed with the work gear 14, which is preferably performed.

  Next, in step S106, the work gear 14 on which the tooth surface 28 is formed in step S105 is removed from the machining portion of the gear machining apparatus 10 and carried out by the gear attaching / detaching apparatus 11 (gear carrying-out process).

  The gear carry-out process in step S106 is basically the reverse procedure of the gear carry-in process in step S102 described above. That is, in a state where the shaving cutter 20 is stopped after finishing the machining, the shaving cutter 20 is raised in the direction of separating from the work gear 14 and the support shafts 236a and 236b are separated (see FIG. 7B). Thereby, since the work gear 14 is mounted on the mounting surface 300a, the slider 306 is retracted, and the work gear 14 is detached from the processing portion. Then, what is necessary is just to carry out the to-be-cut | geared gear 14 which finished processing by the hand, the robot, etc. from the tooth mounting part 300. FIG. As described above, in the gear attaching / detaching device 11, since the cassette 302 stands by directly under the processing part at the time of processing, the work gear 14 is easily and quickly placed on the tooth mounting unit 300 and carried out after processing. Can be quickly transferred to the next process.

  In step S107, carburizing and quenching are performed by heat treatment of the work gear 14 (heat treatment step). This increases the hardness of the work gear 14.

  In step S108, gear grinding of the work gear 14 is performed (gear grinding step). The gear grinding process is a process in which a grindstone (not shown) having a spiral line is meshed with the work gear 14 and rotated synchronously to finish the tooth surface 28 of the tooth 26. At this time, the work gear 14 is considerably hardened by the heat treatment, but since the chamfering is performed in the chamfering process and the occurrence of the raised portion is suppressed, an excessive load is not applied to the grindstone.

  In step S109, gear honing of the work gear 14 is performed (honing process). The gear honing process is a process in which the tooth surface 28 of the tooth 26 is finished with higher accuracy by rotating the work gear 14 while meshing with an internal grindstone (not shown).

  The tools used in the tooth surface finishing process such as the gear grinding process and the honing process are also provided in the turret mechanism 254 of the gear machining apparatus 10 in the same manner as the phrasing cutter 18 and the like, and are continuously processed. It can also be implemented. In addition, the tooth surface finishing process after heat treatment is not limited to gear grinding and gear honing. For example, any one or more of processes that can finish the tooth surface in a finishing hob process, a reamer process, and the like are performed. What is necessary is just to select according to conditions. Moreover, in the said embodiment, of course, you may perform an end surface cutting process, an internal diameter honing process, etc. as needed besides the specified process.

  Each step in step S103, step S104 (or step S105) and steps S107 to S109 can be omitted depending on the required quality and type of the machined gear 14 after machining, which is a product. This is because even if these steps are omitted as appropriate, a gear having sufficient accuracy can be manufactured depending on the required accuracy of the product gear.

  Next, for example, the gear according to the present embodiment is illustrated while exemplifying a gear meshing control method (meshing position control method) between the tool and the work gear, which is performed between step S103 and step S104 described above. The processing method will be described in more detail.

This gear meshing control method is implemented as a part of the gear machining method shown in FIG. 14 , for example. Therefore, in the following, a method for controlling the meshing between the work gear and the tool in the process from the chamfering process in step S103 to the first shaving process in step S104 after the initial meshing in step S102 described above will be exemplified. Now, a gear machining method according to the present embodiment will be described. Of course, this gear meshing control method can also be applied to meshing between another tool and the work gear, and furthermore, the work gear can be pivoted without tool change using a turret mechanism. Even if it is the structure which processes sequentially, moving the supporting shaft to support to the process part of another apparatus, it is applicable.

First, the gear loading step of step S102, the workpiece gear 14 let have properly meshed with the phrasing cutter 18 by meshing rolling described above, in step S103 of FIG. 14, the support shaft 236a of the non-self-supporting drive, to 236b to be Chamfering is performed with the cutting gear 14 pivotally supported (first machining step) (see FIGS. 15A to 15C).

  Here, in the gear meshing control method, the key grooves 18a and 20a used for attaching the phrasing cutter 18 and the shaving cutter 20 to the processing shaft (J2, J3, 262a, etc.) of the processing device (see FIGS. 2 and 4). Is set in advance as the reference position of the cutter.

  That is, as shown in FIG. 17, for example, in the case of the phrasing cutter 18, on the straight line L1 passing through the center of the keyway 18a from the center point P3, the center of the tooth tip that is the meshing reference point of the predetermined processing teeth 32a, 32b. It is set so that there is Pc (which may be the center of the tooth base), that is, the phase positions of the key groove 18a and the processing teeth 32a, 32b are matched. As apparent from FIG. 17, when the cutting direction (vertical direction), which is the direction connecting the center points of the tool and the work gear, is a straight line L0, a straight line is obtained when the center of the key groove 18a coincides with the straight line L1. L1 coincides with the straight line L0.

  Thus, by controlling the rotational phase of the spindle motor 260 (see FIG. 6) composed of the servo motor capable of servo control as described above, the key groove 18a is used as a reference position, for example, as shown in FIG. It is possible to easily match the tooth center Pc of the predetermined processing teeth 32a and 32b on the straight line L0 that is the most advanced position (lowermost position) in the direction (vertical direction). For example, if the position of the key groove 18a is made to coincide with the cutting direction, the tooth center Pc of the processing teeth 32a and 32b also coincides with it.

  In this case, for example, when the number of teeth of the machining teeth 32a and 32b is an even number, the tip center Pc of the machining teeth 32a and 32b on the opposite side is the most advanced in the cutting direction even when the key groove 18a is vertically upward. It corresponds to the position (straight line L0). In other words, 1 is calculated from the number of teeth of the machining teeth 32a and 32b based on the phase of the reference position, which is the stop position of the keyway 18a, regardless of whether the number of teeth of the machining teeth 32a and 32b is even or odd. By rotating the phrasing cutter 18 by a predetermined angle on the basis of the angle of the tooth (one pitch), the phase is shifted, and any one of the processing teeth 32a and 32b is made to coincide with the straight line L0, thereby processing the teeth 32a and 32b. Can be the most advanced position in the cutting direction. For the shaving cutter 20, the reference position, the meshing reference point, etc. may be set in the same manner, and the gear meshing control method can be applied if the grindstone used in the above-described gear grinding process and honing process is set similarly. can do.

  Therefore, after the chamfering process is finished, the rotation of the phrasing cutter (first cutter) 18 is stopped, and any one of the processing teeth 32a, based on the key groove 18a that is a reference position of the framing cutter 18 set in advance, The tooth center Pc, which is the meshing reference point 32b, is made to coincide with the straight line L0 that is the most advanced position (the lowest position in the vertical direction) in the cutting direction (see FIG. 18A). That is, the key groove 18a may coincide with the most advanced position (in this case, the straight line L0 coincides with the straight line L1 in FIG. 18A), or as described above, based on the phase of the stop position of the key groove 18a The tip center Pc of the processed teeth 32a and 32b may coincide with the most advanced position. At this time, since the phrasing cutter 18 and the work gear 14 are still in meshing state, the teeth 26 of the work gear 14 are also rotated to a predetermined meshing position along with the machining teeth 32a and 32b, and the next shaving cutter is obtained. This position is suitable for meshing with 20.

  As shown in FIG. 19, in order to further reduce the time required for meshing, when the phrasing cutter 18 is stopped, the center of the tooth tip of the processing teeth 32a and 32b closest to the straight line L0, which is the most advanced position, is used. If phase control (angle correction) is performed so that Pc1 coincides with the straight line L0 (the most advanced position), the rotation angle after stopping the phrasing cutter 18 is substantially set to the rotation angle corresponding to one tooth of the processing teeth 32a and 32b. It can be adjusted within, so it is efficient and quick. Of course, the same phase control may be performed in the case of a shaving cutter 20 described later shown in FIG. 18B.

  Further, as the reference position, other than the keyway, for example, a mark for matching the mounting phase of the processing tool mounting shaft of the gear processing apparatus and the processing tool may be used. In short, when a drive device for driving a machining tool (cutter) independently, such as the spindle motor 260 and the drive board 206 of the gear machining device 10, has a drive control mechanism (for example, a servo mechanism), the drive control mechanism It suffices if the configuration is such that the phase of the cutting teeth of the cutter can be accurately controlled.

  Next, the phase controlling phrasing cutter 18 is retracted (raised), and the turret mechanism 254 uses the shave cutter (second cutter) used in the first shaving step (step S104) as the next processing step. ) Determine 20 At this time, the phrasing cutter 18 may be separated from the work gear 14, the support shafts 236 a and 236 b may be removed, and the work gear 14 may be in a free state in the tooth mounting unit 300 of the cassette 302.

  Subsequently, as shown in FIG. 18B, the tooth tip center Pc, which is the meshing reference point of the processed tooth 44, is also the most advanced position in the cutting direction based on the key groove 20a that is the reference position for the determined shaving cutter 20 as well. It is made to correspond to the straight line L0 which is (the lowest position in the vertical direction). This operation can be performed in substantially the same manner as in the case of the phrasing cutter 18 (meshing step).

  Therefore, as shown in FIG. 18C, the machining teeth 44 can be smoothly meshed with the teeth 26 of the work gear 14 simply by moving the shaving cutter 20 forward (down), and the next first shaving process ( The second processing step) can be started quickly. At this time, since the work gear 14 is in a free state in the tooth mounting unit 300, the work gear 14 can move somewhat, and the shaving cutter 20 can be engaged more smoothly.

  Such a gear meshing control method is performed, for example, in the gear machining apparatus 10 under NC control of the drive panel 206 serving as a control unit.

  As described above, according to the gear machining method according to the present embodiment including the gear meshing control method, when machining the work gear by sequentially performing at least two machining steps (first and second machining steps). By using setting data, which is meshing position information (meshing phase information) between the machining teeth of the first cutter (phraseing cutter 18) used in the previous machining process and the teeth of the workpiece gear 14, the subsequent machining is performed. The process teeth of the second cutter (shaving cutter 20) used in the process and the teeth of the work gear 14 can be meshed smoothly and in a short time (meshing process), which is efficient. Therefore, the loss time due to the meshing error at the time of tool change can be reduced as much as possible, and the production efficiency can be improved.

  Further, for example, when the tooth tip center Pc (or the center of the tooth bottom), which is the meshing reference point of the processed teeth of the second cutter (shaving cutter 20) after the tool change, is set to the foremost position in the cutting direction (see FIG. 18B), based on the reference position, it may be controlled so that the tip center Pc of the different machining teeth coincides with the straight line L0 sequentially for each machining process (for each gear to be cut). As a result, the machining start position of the cutter can be appropriately changed for each machining process, so that uneven tool wear can be prevented and the tool life can be extended. In addition, since the first cutter (phrasing cutter 18) to be meshed first is meshed by a rolling method, the machining start position for each machining process can be changed randomly, thus preventing uneven tool wear. Can do.

  The present invention is not limited to the above-described embodiment, and it goes without saying that various configurations and processes can be adopted without departing from the gist of the present invention.

DESCRIPTION OF SYMBOLS 10 ... Gear processing apparatus 11 ... Gear attaching / detaching apparatus 12 ... Chamfering processing part 13 ... Shaving processing part 14 ... Workpiece gear 18 ... Phrasing cutter 18a, 20a ... Key groove 20 ... Shaving cutter 26 ... Teeth 28 ... Tooth surfaces 32a, 32b, 44 ... Processing teeth 236a, 236b ... Support shaft 254 ... Turret mechanism 300 ... Teeth on-board placement part 302 ... Cassette 304 ... Post 306 ... Slider 308 ... Guide rail 310 ... Base 316 ... Shaft 322 ... Coil spring 334, 336, 338 ... Cutting Lack

Claims (8)

A gear machining method for machining a workpiece gear in a plurality of machining steps by sequentially using a plurality of cutters that are driven independently.
A first machining step in which the workpiece gear is pivotally supported in a non-self-supporting drive, and the teeth of the first cutter are meshed with the teeth of the workpiece gear to process the teeth;
After the first machining step, the first cutter is rotated by a predetermined angle based on a preset reference position of the first cutter, and the meshing reference point of the processed teeth of the first cutter is cut direction after matching the cutting edge position in was replaced with the second cutter is retracted the first cutter, the meshing step of meshing the teeth of the second forming teeth and the workpiece gear cutter ,
After the meshing step, a second machining step of machining the teeth of the work gear by the second cutter;
A gear machining method comprising: The gear machining method according to claim 1 ,
In the meshing step, the second cutter is further rotated by a predetermined angle based on a reference position preset for the replaced second cutter, and the meshing reference point of the processing teeth of the second cutter A gear machining method, wherein the second cutter is moved forward and meshed with the work gear after matching the cutting edge with the most advanced position in the cutting direction. The gear machining method according to claim 1 or 2 ,
The gear processing method, wherein the reference position is a keyway. In the gear machining method according to any one of claims 1 to 3 ,
The gear processing method, wherein the meshing reference point is a center of a tip or a center of a root of the processed tooth. The gear machining method according to claim 1,
A gear machining method, wherein a drive device for driving the cutter independently has a drive control mechanism. The gear machining method according to claim 5 , wherein
The gear machining method, wherein the drive control mechanism is a servo mechanism. The gear machining method according to claim 1,
In the meshing step, after completion of the first machining step, the cassette that is elastically supported by the column is removed by removing a support shaft that pivotally supports the workpiece gear by the non-self-supporting drive from the workpiece gear. After the work gear is placed and the first cutter is replaced with the second cutter, the second cutter and the work gear placed on the cassette are engaged with each other. Gear processing method. The gear machining method according to claim 1 or 7 ,
In the first machining step, a gear attaching / detaching device having a cassette on which the work gear is placed and a support column that elastically supports the cassette is used, and the work gear is placed on the cassette at the time of machining. by sending to the meshing position between the first cutter being rotated at a low speed than gear cutting method characterized by causing meshing rolling with the first cutter and the workpiece gear.

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