JP7052194B2 - Gear processing equipment and gear processing method - Google Patents

Description

The present invention relates to a gear processing apparatus and a gear processing method for processing gears by cutting by rotating a processing tool and a workpiece synchronously.

The transmission used in the vehicle is provided with a synchromesh mechanism for smooth shifting operation. As shown in FIG. 17, the key-type synchromesh mechanism 110 includes a main shaft 111, a main drive shaft 112, a clutch hub 113, a key 114, a sleeve 115, a main drive gear 116, a clutch gear 117, a synchronizer ring 118, and the like. Be prepared. The main drive gear 116, the clutch gear 117, and the synchronizer ring 118 are arranged on both sides of the sleeve 115.

The main shaft 111 and the main drive shaft 112 are coaxially arranged. A clutch hub 113 is spline-fitted to the main shaft 111, and the main shaft 111 and the clutch hub 113 rotate together. Keys 114 are supported by springs (not shown) at three locations on the outer circumference of the clutch hub 113. Internal teeth (splines) 115a are formed on the inner circumference of the sleeve 115, and the sleeve 115 slides in the rotation axis LL direction along the spline of the figure formed on the outer periphery of the clutch hub 113 together with the key 114.

A main drive gear 116 is fitted to the main drive shaft 112, and a clutch gear 117 having a tapered cone 117b projecting is integrally formed on the sleeve 115 side of the main drive gear 116. A synchronizer ring 118 is arranged between the sleeve 115 and the clutch gear 117. The external teeth 117a of the clutch gear 117 and the external teeth 118a of the synchronizer ring 118 are formed so as to be meshable with the internal teeth 115a of the sleeve 115. The inner circumference of the synchronizer ring 118 is formed in a tapered shape capable of frictionally engaging with the outer circumference of the taper cone 117b.

Next, the case where the synchromesh mechanism 110 operates to the left side of FIG. 17 will be described, but the same applies to the case where the synchromesh mechanism 110 operates to the right side of FIG. As shown in FIG. 18A, the sleeve 115 and the key 114 are moved in the direction of the rotation axis LL of the arrow shown by the operation of the shift lever (not shown). The key 114 pushes the synchronizer ring 118 in the direction of the rotation axis LL, and presses the inner circumference of the synchronizer ring 118 against the outer circumference of the tapered cone 117b. As a result, the clutch gear 117, the synchronizer ring 118 and the sleeve 115 start synchronous rotation.

Then, as shown in FIG. 18B, the key 114 is pushed down by the sleeve 115 to further push the synchronizer ring 118 in the rotation axis LL direction, so that the degree of adhesion between the inner circumference of the synchronizer ring 118 and the outer circumference of the taper cone 117b is high. Further, a strong frictional force is generated, and the clutch gear 117, the synchronizer ring 118, and the sleeve 115 rotate synchronously. When the rotation speed of the clutch gear 117 and the rotation speed of the sleeve 115 are completely synchronized, the frictional force between the inner circumference of the synchronizer ring 118 and the outer circumference of the taper cone 117b disappears.

Then, when the sleeve 115 and the key 114 further move in the direction of the rotation axis LL shown by the arrow, the key 114 fits into the groove 118b of the synchronizer ring 118 and stops, but the sleeve 115 moves beyond the convex portion 114a of the key 114. , The inner teeth 115a of the sleeve 115 mesh with the outer teeth 118a of the synchronizer ring 118. Then, as shown in FIG. 18C, the sleeve 115 further moves in the direction of the rotation axis LL of the arrow shown in the drawing, and the internal teeth 115a of the sleeve 115 mesh with the external teeth 117a of the clutch gear 117. The shift is completed by the above.

In the synchromesh mechanism 110 as described above, in order to prevent the external teeth 117a of the clutch gear 117 and the internal teeth 115a of the sleeve 115 from coming off during traveling, the inside of the sleeve 115 is shown in FIGS. 19 and 20. A tapered gear disengagement prevention portion is provided on one side (hereinafter, simply referred to as the rotation axis one side Db) and the other side (hereinafter, simply referred to as the rotation axis other side Df) of the sleeve 115 in the tooth 115a in the rotation axis LL direction. 120B and 120F are provided, and the outer teeth 117a and 117a of each clutch gear 117 are provided with tapered gear disengagement prevention portions 117c and 117c that are tapered and fitted with the gear disengagement prevention portions 120B and 120F.

In FIG. 20, the external teeth 117a of the clutch gear 117 show only the gear disengagement prevention portion 120F side. The gear disengagement prevention portions 120B and 120F of this example are formed in a point-symmetrical shape with respect to a virtual point at the center of the sleeve 115 in the rotation axis LL direction on the top surface of the internal teeth 115a. In the following description, the side surface 115A on the left side of the figure of the internal teeth 115a of the sleeve 115 is referred to as the left side surface 115A, and the side surface 115B on the right side of the figure of the internal teeth 115a of the sleeve 115 is referred to as the right side surface 115B.

The left side surface 115A of the internal teeth 115a of the sleeve 115 is the rotation axis of the left side surface 115A so that the twist angle is different from that of the left tooth surface 115b (corresponding to the "first tooth surface" of the present invention) and the left tooth surface 115b. Rotation of the left side surface 115A so that the twist angle is different from that of the tooth surface 121f provided on the side Df (hereinafter referred to as the other side left tapered tooth surface 121f, which corresponds to the "second tooth surface" of the present invention) and the left tooth surface 115b. It has a tooth surface 122b provided on one side Db of the axis (hereinafter referred to as a one-side left tapered tooth surface 122b, which corresponds to the "third tooth surface" of the present invention).

Further, the right side surface 115B of the internal teeth 115a of the sleeve 115 is one of the rotation axes of the right side surface 115B so that the twist angle is different from that of the right tooth surface 115c (corresponding to the "fourth tooth surface" of the present invention) and the right tooth surface 115c. Rotation of the right side surface 115B so that the twist angle is different from that of the tooth surface 121b provided on the side Db (hereinafter referred to as the one-side right tapered tooth surface 121b, which corresponds to the "fifth tooth surface" of the present invention) and the right tooth surface 115c. It has a tooth surface 122f provided on the other side Df of the axis (hereinafter referred to as a right tapered tooth surface 122f on the other side, which corresponds to the "sixth tooth surface" of the present invention).

In this example, the helix angle of the left tooth surface 115b is 0 degrees, and the helix angle of the left tapered tooth surface 121f on the other side and the right tapered tooth surface 121b on the one side is θf degrees. The helix angle of the right tooth surface 115c is 0 degrees, and the helix angle of the left tapered tooth surface 122b on one side and the right tapered tooth surface 122f on the other side is θb degrees. Then, the tooth surface 121af connecting the other side left tapered tooth surface 121f and the other side left tapered tooth surface 121f and the left tooth surface 115b (hereinafter referred to as the other side left sub tooth surface 121af), and the other side right tapered tooth surface 122f and The tooth surface 122af connecting the other side right tapered tooth surface 122f and the right tooth surface 115c (hereinafter referred to as the other side right sub tooth surface 122af) constitutes the gear disengagement prevention portion 120F.

Then, the one-side left tapered tooth surface 122b, the tooth surface 122ab connecting the one-side left tapered tooth surface 122b and the left tooth surface 115b (hereinafter referred to as one-side left sub-tooth surface 122ab), and the one-side right tapered tooth surface 121b and The tooth surface 121ab (hereinafter referred to as the one-side right sub-tooth surface 121ab) connecting the one-side right tapered tooth surface 121b and the right tooth surface 115c constitutes the gear disengagement prevention portion 120B. To prevent gear disengagement, the left tapered tooth surface 121f on the other side and the gear disengagement prevention portion 117c are tapered and fitted, and the right tapered tooth surface 121b on one side and the gear disengagement prevention portion 117c are tapered and fitted. Achieved by

As described above, the structure of the internal teeth 115a of the sleeve 115 is complicated, and the sleeve 115 is a part that requires mass production. Therefore, in general, the internal teeth 115a of the sleeve 115 are broached, gear shaper processed, or the like. The gear disengagement prevention portions 120F and 120B are formed by rolling processing (see Patent Documents 1 and 2). However, since the rolling process is a plastic process, the machining accuracy of the gear disengagement prevention portions 120F and 120B tends to be low.

Cutting is desirable to improve machining accuracy. However, as described above, the gear disengagement prevention portions 120B and 120F are provided on one side Db of the rotation axis and the other side Df of the rotation axis of the internal teeth 115a of the sleeve 115. Therefore, in the gear processing device, a processing tool for processing the gear disengagement prevention portion 120B on one side Db of the rotary axis and a processing tool for processing the gear disengagement prevention portion 120F on the other side Df of the rotary axis. It is necessary to replace the tools and align each tool. Therefore, the processing time tends to be long and the processing accuracy tends to be low.

Patent Documents 3 and 4 describe a machining tool having two blades, but since one blade is for roughing and the other blade is for finishing, one tool for machining is described. It is not possible to process the gear disengagement prevention portions 120B and 120F having the above configuration. Further, Patent Document 5 describes that the machining tool is advanced and retracted to perform machining, respectively, but the machining is performed on the same tooth, and the above-mentioned one machining tool is used for machining. It is not possible to process the two gear disengagement prevention portions 120B and 120F having the above configuration.

Jikkenhei 6-61340 Gazette Japanese Unexamined Patent Publication No. 2005-152940 Japanese Unexamined Patent Publication No. 2015-217485 Japanese Unexamined Patent Publication No. 2004-160645 Japanese Unexamined Patent Publication No. 2014-172112

As described above, in the gear processing apparatus, a processing tool for processing the gear disengagement prevention portion 120B on one side Db of the rotary axis and a processing tool for processing the gear disengagement prevention portion 120F on the other side Df of the rotary axis. It is necessary to replace the tool with the tool and to perform alignment for each tool. Therefore, the processing time tends to be long and the processing accuracy tends to be low.

The present invention has been made in view of such circumstances, and is a gear processing device capable of processing tooth surfaces having different helix angles provided on one side and the other side in the rotation axis direction of the gear with high efficiency and high accuracy. And to provide a gear machining method.

One aspect of the present invention is
A workpiece support device that rotatably supports gears as a workpiece,
Machining tools and
A tool support device that rotatably supports the machining tool,
In order to machine the gear teeth on the workpiece, the machining tool is rotated in synchronization with the workpiece in a state where the rotation axis of the machining tool is tilted with respect to the rotation axis of the workpiece. A control device that controls the relative movement of the workpiece in the direction of the rotation axis, and
It is a gear processing device equipped with
On the side surface of the tooth of the gear, a pair of subordinate tooth surfaces having a different helix angle and a different helix angle from the main tooth surface with respect to the surface on which the main tooth surface has been processed in advance . It is configured to machine on one side and the other side in the direction of the rotation axis of the workpiece , respectively.
The processing tool is
The first tool blade whose rake surface faces one side in the direction of the rotation axis of the machining tool,
A second tool blade whose rake surface faces the other side in the direction of the rotation axis of the machining tool ,
Have,
The control device is
A predetermined crossing angle is set, the machining tool is relatively moved to one side in the rotation axis direction of the workpiece , and the first tool blade is used to move the machining tool to the other side in the rotation axis direction of the workpiece. Controlled to process one of the pair of subordinate tooth surfaces provided on the side,
The machining tool is set to an crossing angle different from the crossing angle when machining one of the pair of subordinate tooth surfaces provided on the other side in the rotation axis direction of the workpiece with the first tool blade. Using the second tool blade, the pair of subordinate tooth surfaces provided on one side in the rotation axis direction of the work piece are moved relative to the other side in the rotation axis direction of the work piece . It is in a gear machining device that controls to machine the other .

As a result, the gear machining apparatus can form a plurality of tooth surfaces having different helix angles on both end faces of the workpiece with one machining tool. There is no need to perform alignment, processing efficiency can be improved, and processing accuracy can be improved.

Another aspect of the present invention is
In a state where the rotation axis of the machining tool is tilted with respect to the rotation axis of the workpiece, the machining tool is rotated in synchronization with the workpiece while being relatively moved in the direction of the rotation axis of the workpiece. A gear processing method for cutting gear teeth on the work piece .
On the side surface of the tooth of the gear, a pair of subordinate tooth surfaces having a different helix angle and a different helix angle from the main tooth surface with respect to the surface on which the main tooth surface has been processed in advance . The workpiece is processed on one side and the other side in the direction of the rotation axis, respectively.
The processing tool is
The first tool blade whose rake surface faces one side in the direction of the rotation axis of the machining tool,
A second tool blade whose rake surface faces the other side in the direction of the rotation axis of the machining tool ,
Have,
The gear processing method is
The machining tool is set to a predetermined crossing angle, and the machining tool is moved relative to one side in the rotation axis direction of the workpiece while rotating synchronously with the workpiece. The first processing step of processing one of the pair of subordinate tooth surfaces provided on the other side in the rotation axis direction of the work piece,
In the first machining step, the crossing angle is set to be different from the crossing angle when machining one of the pair of slave tooth surfaces provided on the other side in the rotation axis direction of the workpiece with the first tool blade. While rotating the machining tool synchronously with the workpiece , the machining tool is relatively moved to the other side in the rotation axis direction of the workpiece , and the second tool blade is used to move the machining tool in the rotation axis direction of the workpiece. A second processing step of processing the other of the pair of slave tooth surfaces provided on one side,
It is in the gear processing method.
According to the gear processing method, the same effect as that of the gear processing apparatus described above is obtained.

It is a figure which shows the whole structure of the gear processing apparatus which concerns on embodiment of this invention. It is a flowchart for demonstrating the tool design process by the control device of FIG. It is a flowchart for demonstrating the tool state setting process by the control device of FIG. It is a flowchart for demonstrating the machining control processing by the control apparatus of FIG. It is a flowchart which shows the continuation of the flow of FIG. 4A for demonstrating the machining control processing by the control apparatus of FIG. It is the figure which looked at the schematic structure of the machining tool from the tool end face side in the direction of the rotation axis. FIG. 5 is a partial cross-sectional view of the schematic configuration of the machining tool of FIG. 5A as viewed in the radial direction. FIG. 5B is an enlarged view of a tool blade of the machining tool of FIG. 5B. It is a perspective view which shows the color which constitutes the processing tool. It is a figure which shows the state which the machining tool is assembled with the tool holder and the rotary spindle. It is a 1st figure which shows the dimensional relationship between a machining tool and a work piece at the time of designing the 1st tool of a machining tool. It is a 1st figure which shows the positional relationship between a machining tool and a work piece at the time of designing the 1st tool of a machining tool. It is a second figure which shows the dimensional relationship between a machining tool and a work piece at the time of designing the first tool of a machining tool. It is a second figure which shows the positional relationship between a machining tool and a work piece at the time of designing the first tool of a machining tool. It is a figure which shows each part of the machining tool used when determining the cutting edge width and the cutting edge thickness of a machining tool. It is the figure which looked at the schematic structure of the 1st tool (the 2nd tool) of a machining tool in the radial direction. It is a figure which shows the positional relationship between a machining tool and a work piece when the tool position in the direction of the rotation axis of a machining tool is changed. It is the first figure which shows the processing state when the position in the axial direction is changed. It is a second figure which shows the processing state when the position in the axial direction is changed. It is a third figure which shows the processing state when the position in the axial direction is changed. It is a figure which shows the positional relationship between a machining tool and a workpiece when changing the crossing angle which shows the inclination of the rotation axis of a machining tool with respect to the rotation axis of a workpiece. It is the first figure which shows the processing state when the intersection angle is changed. It is a second figure which shows the processing state when the intersection angle is changed. It is a third figure which shows the processing state when the intersection angle is changed. It is a figure which shows the positional relationship between a machining tool and a work piece at the time of changing the rotation axis direction position and the crossing angle of a machining tool. It is the first figure which shows the processing state when the position in the axial direction and the crossing angle are changed. It is a second figure which shows the processing state when the position in the axial direction and the crossing angle are changed. It is the figure which looked at the position of the machining tool before machining the left tapered tooth surface on the other side in the radial direction. It is the figure which looked at the position of the machining tool in the radial direction when machining the left tapered tooth surface on the other side. It is the figure which looked at the position of the machining tool after machining the left tapered tooth surface on the other side in the radial direction. It is a 2nd figure which shows the dimensional relationship between a machining tool and a work piece at the time of designing the 2nd tool of a machining tool. It is a 2nd figure which shows the positional relationship between a machining tool and a work piece at the time of designing the 2nd tool of a machining tool. It is the figure which looked at the position of the machining tool before machining the one side left tapered tooth surface in the radial direction. It is the figure which looked at the position of the machining tool when machining the one side left tapered tooth surface in the radial direction. It is the figure which looked at the position of the machining tool after machining the one side left tapered tooth surface in the radial direction. It is sectional drawing which shows the synchromesh mechanism which has a sleeve which is a work piece. It is sectional drawing which shows the state before the operation start of the synchromesh mechanism of FIG. It is sectional drawing which shows the operating state of the synchromesh mechanism of FIG. It is sectional drawing which shows the state after the operation completion of the synchromesh mechanism of FIG. It is a perspective view which shows the gear disengagement prevention part of the sleeve which is a work piece. FIG. 18 is a view of the gear disengagement prevention portion of the sleeve of FIG. 18 as viewed from the radial direction.

(1. Mechanical configuration of gear processing equipment)
In the present embodiment, a 5-axis machining center will be taken as an example of a gear processing apparatus, and will be described with reference to FIG. That is, the gear processing device 1 has three linear axes (X, Y, Z axes) orthogonal to each other and two rotation axes (A axis parallel to the X axis and C axis perpendicular to the A axis) as drive axes. ).

Here, as described in the background technology, the gear disengagement prevention portions 120B and 120F perform cutting with two processing tools on the internal teeth 115a of the sleeve 115 formed by broaching, gear shaper processing, or the like. Since it is formed by, it is necessary to change the tool and align each tool, the machining time is long, and the machining accuracy tends to be low. Therefore, in the above-mentioned gear processing apparatus 1, first, the internal teeth 115a of the sleeve 115 are formed by broaching, gear shaper processing, or the like, and then two tool blades (first tool blade 42af, second tool blade 42ab) described later are formed. (See FIG. 5B)), the gear disengagement prevention portions 120F and 120B are formed with respect to the internal teeth 115a of the sleeve 115 by cutting with one machining tool 42.

That is, the sleeve 115 on which the internal teeth 115a are formed and the machining tool 42 are rotated synchronously, and the first tool blade 42af of the machining tool 42 is rotated from the rotation axis other side Df to the rotation axis one side Db. A gear disengagement prevention portion 120F is formed by feeding in the axis Lw direction for cutting, and the second tool blade 42ab of the machining tool 42 is moved from one side Db of the rotary axis to the other Df of the rotary axis to the rotary axis Lw of the workpiece W. The gear disengagement prevention portion 120B is formed by feeding in the direction and cutting. This eliminates the need for tool replacement and alignment of each tool, shortens the machining time of the gear disengagement prevention portions 120F and 120B, and improves the machining accuracy of the gear disengagement prevention portions 120F and 120B (FIGS. 19 and 19). See FIG. 20).

As shown in FIG. 1, the gear processing apparatus 1 includes a bed 10, a column 20, a saddle 30, a rotary spindle 40, a table 50, a tilt table 60, a turntable 70, and a workpiece holder 80. , The control device 100 and the like. Although not shown, a known automatic tool changer is provided along with the bed 10.

The bed 10 has a substantially rectangular shape and is arranged on the floor. An X-axis ball screw (not shown) for driving the column 20 in a direction parallel to the X-axis line is arranged on the upper surface of the bed 10. An X-axis motor 11c that rotationally drives the X-axis ball screw is arranged on the bed 10.

A Y-axis ball screw (not shown) for driving the saddle 30 in a direction parallel to the Y-axis is arranged on the side surface (sliding surface) 20a parallel to the Y-axis of the column 20. A Y-axis motor 23c that rotationally drives the Y-axis ball screw is arranged on the column 20.

The rotary spindle 40 supports the machining tool 42, is rotatably supported in the saddle 30, and is rotated by the spindle motor 41 housed in the saddle 30. The machining tool 42 is held by the tool holder (not shown), fixed to the tip of the rotary spindle 40, and rotates with the rotation of the rotary spindle 40. Further, the machining tool 42 moves in a direction parallel to the X-axis line and a direction parallel to the Y-axis line with respect to the bed 10 as the column 20 and the saddle 30 move. The details of the machining tool 42 will be described later.

Further, on the upper surface of the bed 10, a Z-axis ball screw (not shown) for driving the table 50 in a direction parallel to the Z-axis line is arranged. A Z-axis motor 12c that rotationally drives the Z-axis ball screw is arranged on the bed 10.

A tilt table support portion 63 that supports the tilt table 60 is provided on the upper surface of the table 50. The tilt table support portion 63 is provided with a tilt table 60 that can rotate (swing) around an axis parallel to the A axis. The tilt table 60 is rotated (swinged) by an A-axis motor 61 housed in the table 50.

The tilt table 60 is provided with a turntable 70 rotatably around an axis parallel to the C axis. The turntable 70 is equipped with a workpiece holder 80 that holds the sleeve 115 as a workpiece. The turntable 70 is rotated by a C-axis motor 62 together with the sleeve 115 and the workpiece holder 80.

The control device 100 includes a machining control unit 101, a tool design unit 102, a tool state calculation unit 103, a storage unit 104, and the like. Here, the machining control unit 101, the tool design unit 102, the tool state calculation unit 103, and the storage unit 104 can be configured by individual hardware or can be realized by software.

The machining control unit 101 controls the spindle motor 41 to rotate the machining tool 42, and controls the X-axis motor 11c, the Z-axis motor 12c, the Y-axis motor 23c, the A-axis motor 61, and the C-axis motor 62. , The sleeve 115 and the machining tool 42 move relative to each other in the direction parallel to the X axis, the direction parallel to the Z axis, the direction parallel to the Y axis, the axis parallel to the A axis, and the axis parallel to the C axis. As a result, the sleeve 115 is machined.

Although the details of the tool design unit 102 will be described later, the twist angle β of the first tool blade 42af and the second tool blade 42ab of the machining tool 42, in this example, the first tool blade 42af and the second tool blade 42ab have the same shape. Therefore, the machining tool 42 is designed by obtaining the same twist angle β (see FIG. 5C) and the like. Although the details will be described later, the machining tool 42 is configured by integrating the first tool 42F having the first tool blade 42af and the second tool 42B having the second tool blade 42ab having the same shape as the first tool 42F. ..
The tool state calculation unit 103 calculates the tool state, which is the relative position and posture of the machining tool 42 with respect to the sleeve 115, although the details will be described later.

In the storage unit 104, tool data relating to the first tool 42F and the second tool 42B, that is, the cutting edge circle diameter da, the reference circle diameter d, the cutting edge ha, the module m, the shift coefficient λ, the pressure angle α, and the front pressure angle Machining data for cutting αt, the cutting edge pressure angle αa, and the sleeve 115 are stored in advance. Further, the storage unit 104 stores the number Z of the first tool blade 42af and the second tool blade 42ab, which are input when designing the first tool 42F and the second tool 42B, and also stores the tool design unit 102. The shape data of the first tool 42F and the second tool 42B designed in 1 and the tool state calculated by the tool state calculation unit 103 are stored.

(2. Machining tool)
As shown in FIGS. 5A and 5B, the machining tool 42 includes a first tool 42F, a second tool 42B, and a collar 44 sandwiched between the first tool 42F and the second tool 42B, and in this example, the first tool. The 42F and the second tool 42B are tools having the same shape. In the machining tool 42, the first tool 42F is arranged so that the rake face 42cf of the first tool blade 42af of the first tool 42F faces one side of the tool axis (rotary axis) L direction of the machining tool 42. The second tool 42B is arranged so that the rake face 42cc of the second tool blade 42ab of the second tool 42B faces the other side of the tool axis L direction of the machining tool 42, and is between the first tool 42F and the second tool 42B. The color 44 is arranged in the.

As shown in FIG. 5A, the shape of the first tool blade 42af (second tool blade 42ab) when the machining tool 42 is viewed from the tool end surface 42M side of the first tool 42F in the tool axis L direction is shown in this example. It is formed in the same shape as the involute curve shape. Then, as shown in FIG. 5B, the first tool blade 42af of the first tool 42F and the second tool blade 42ab of the second tool 42B have an angle γ with respect to a plane perpendicular to the tool axis L on the tool end surface 42M side. An inclined rake angle is provided, and a front clearance angle inclined by an angle δ is provided on the tool peripheral surface 42N side with respect to a straight line parallel to the tool axis L. Then, as shown in FIG. 5C, the blade streaks 42bf (42bb) of the first tool blade 42af (second tool blade 42ab) have a twist angle inclined by an angle β with respect to a straight line parallel to the tool axis L.

As shown in FIG. 6, the collar 44 is formed in a cylindrical shape, and two rectangular parallelepiped detent keys 44a extending in the radial direction at 180-degree intervals are provided on both end faces of the collar 44, respectively. As shown in FIG. 7, when assembling the machining tool 42 to the tool holder 45, first, the second tool 42B is attached to the tool mounting shaft 45a on the tip side of the tool holder 45, and the second tool blade 42ab is attached to the tool holder 45. Insert it so that it faces the main body 45b side, and then insert the collar 44.

Next, the first tool 42F is inserted so that the first tool blade 42af faces the tip side (outside) of the tool mounting shaft 45a, and finally the bolt 45d with a washer is inserted into the screw hole 45c provided at the tip of the tool mounting shaft 45a. To conclude. At this time, each key 44a of the collar 44 is fitted into the key groove 42ef provided in the shaft portion 42df of the first tool 42F and the key groove 42eb provided in the shaft portion 42db of the second tool 42B. As a result, the first tool blade 42af of the first tool 42F and the second tool blade 42ab of the second tool 42B can rotate in the same phase.

The tool holder 45 to which the machining tool 42 is attached is stored in the tool stocker of the automatic tool changer, is taken out from the tool stocker by the tool changer arm of the automatic tool changer before the start of machining, and is attached to the rotary spindle 40. At this time, the key 45e provided in the tool holder 45 is fitted into the key groove 40a provided in the rotary spindle 40. Although there is play between the key 45e of the tool holder 45 and the key groove 40a of the rotary spindle 40, the rotary spindle 40 is rotated while holding the tool holder 45 to which the machining tool 42 is attached by the tool change arm. Then, the backlash is clogged and the rotation phase of the machining tool 42 with respect to the rotation spindle 40 is set. After that, the tool holder 45 is clamped on the rotary spindle 40, and the holding of the tool holder 45 by the tool change arm is released.

Here, the other side left tapered tooth surface 121f (one side right tapered tooth surface 121b) and the other side right tapered tooth surface 122f (one side left tapered tooth surface 122b) having different twist angles in the first tool 42F (second tool 42B). ), A method using a machining tool 42 in which the twist angles of the left blade surface and the right blade surface of the first tool blade 42af (second tool blade 42ab) are different, and a method of using the first tool blade 42af (second tool). A method of using a machining tool 42 having the same twist angle on the left blade surface and the right blade surface of the blade 42ab) can be considered.

In this example, a case where cutting is performed using a machining tool 42 having the same twist angle on the left blade surface and the right blade surface of the first tool blade 42af (second tool blade 42ab) will be described. In this case, the crossing angle φf of the first tool 42F (second tool 42B) when cutting the other side left tapered tooth surface 121f (one side right tapered tooth surface 121b) and the other side right tapered tooth surface 122f (one side). It is necessary to make the cross angle φb of the first tool 42F (second tool 42B) different when cutting the side left tapered tooth surface 122b). Hereinafter, the case of designing the first tool 42F will be described, but since the same applies to the case of designing the second tool 42B, detailed description thereof will be omitted.

As described above, the left tapered tooth surface 121f on the other side of the sleeve 115 is formed by cutting the already formed inner teeth 115a of the sleeve 115 with the first tool 42F. Therefore, the first tool blade 42af of the first tool 42F does not interfere with the adjacent internal teeth 115a during cutting, and the other side left tapered tooth surface 121f including the other side left sub tooth surface 121af. It is necessary to make the shape so that it can be reliably machined.

Specifically, as shown in FIG. 8A, when the first tool blade 42af cuts by the tooth streak length ff of the left tapered tooth surface 121f on the other side, the cutting edge width Sa of the first tool blade 42af becomes the other side. The blade thickness Ta (see FIG. 9) larger than the tooth streak length gf of the left sub tooth surface 121af and on the reference circle Cb of the first tool blade 42af is the other side left tapered tooth surface 121f and the other side left tapered tooth surface. It is necessary to design the first tool blade 42af so as to be smaller than the distance Hf (hereinafter referred to as tooth surface spacing Hf) from the open end portion of the other side right tapered tooth surface 122f facing 121f. At this time, the blade edge width Sa of the first tool blade 42af and the blade thickness Ta on the reference circle Cb of the first tool blade 42af are set in consideration of the durability of the first tool blade 42af, for example, a defect or the like.

In designing the first tool blade 42af, as shown in FIG. 8B, first, the cross angle represented by the difference between the helix angle θf of the left tapered tooth surface 121f on the other side and the helix angle β of the first tool blade 42af. It is necessary to set φf (hereinafter referred to as the cross angle φf of the machining tool 42). The helix angle θf of the left tapered tooth surface 121f on the other side is a known value, and the crossing angle φf of the machining tool 42 is set in a settable range by the gear machining apparatus 1, so that the operator can make any crossing. Temporarily set the angle φf.

Next, the helix angle β of the first tool blade 42af is obtained from the known helix angle θf of the other side left tapered tooth surface 121f and the set cross angle φf of the machining tool 42, and the cutting edge width Sa of the first tool blade 42af and The blade thickness Ta on the reference circle Cb of the first tool blade 42af is obtained. By repeating the above processing, the first tool 42F having the optimum first tool blade 42af for cutting the other side left tapered tooth surface 121f is designed. An example of calculation for obtaining the blade edge width Sa of the first tool blade 42af and the blade thickness Ta on the reference circle Cb of the first tool blade 42af will be described below.

As shown in FIG. 9, the cutting edge width Sa of the first tool blade 42af is represented by the cutting edge circle diameter da and the half-width Ψa of the cutting edge circular blade thickness (see equation (1)).

The cutting edge circle diameter da is represented by the reference circle diameter d and the blade end take ha (see equation (2)), and the reference circle diameter d is the number of blades Z of the first tool blade 42af and the first tool blade 42af. The twist angle β of the blade streak 42bf and the module m (see equation (3)), and the blade end bamboo ha is expressed by the shift coefficient λ and the module m (see equation (4)).

The half-angle Ψa of the cutting edge circular blade thickness is represented by the number of blades Z of the first tool blade 42af, the dislocation coefficient λ, the pressure angle α, the front pressure angle αt, and the cutting edge pressure angle αa (see equation (5)). The front pressure angle αt can be expressed by the pressure angle α and the helix angle β of the blade streak 42bf of the first tool blade 42af (see equation (6)), and the cutting edge pressure angle αa has the front pressure angle αt and the cutting edge. It can be expressed by the circle diameter da and the reference circle diameter d (see equation (7)).

Further, the blade thickness Ta of the first tool blade 42af is represented by a half-width Ψ of the reference circle diameter d and the blade thickness Ta (see equation (8)).

The reference circle diameter d is represented by the number of blades Z of the first tool blade 42af, the helix angle β of the blade streak 42bf of the first tool blade 42af, and the module m (see equation (9)).

The half-angle Ψ of the blade thickness Ta is represented by the number of blades Z of the first tool blade 42af, the dislocation coefficient λ, and the pressure angle α (see equation (10)).

As described above, as shown in FIG. 10, when the tool end surface 42M is viewed from the direction perpendicular to the tool axis L with the tool end surface 42M facing downward in the drawing, the blade streaks 42bf of the first tool blade 42af are at the lower left. It is designed to have a helix angle β that slopes upward to the right. The design of the first tool 42F and the second tool 42B described above is performed by the tool design unit 102 of the control device 100, and the details of the processing will be described later.

(3. Tool state of machining tool in gear machining equipment)
Next, the designed machining tool 42 is applied to the gear machining apparatus 1, and the tool position of the machining tool 42 in the direction of the tool axis L (hereinafter, the axial position of the machining tool 42) is set as the tool state of the machining tool 42. The machining accuracy when the crossing angle φf of the machining tool 42 is changed and the left tapered tooth surface 121f on the other side is machined will be examined. Since the processing accuracy when the other side right tapered tooth surface 122f is machined is the same, detailed description thereof will be omitted.

For example, as shown in FIG. 11A, when the axial position of the machining tool 42, that is, the intersection P between the tool end surface 42M of the machining tool 42 and the tool axis L is located on the rotation axis Lw of the sleeve 115 (offset). Amount 0), when the machining tool 42 is offset by a distance + d in the tool axis L direction (offset amount + d), and when the machining tool 42 is offset by a distance −d in the tool axis L direction (offset amount −d). The other side left tapered tooth surface 121f was machined. The intersection angle φf of the machining tool 42 was set to be constant.

As a result, the processing states of the left tapered tooth surface 121f on the other side are shown in FIGS. 11B, 11C, and 11D. In the figure, the thick solid line E represents the involute curve of the left tapered tooth surface 121f on the other side in design by converting it into a straight line, and the dot portion D represents the cutting-removed portion.

As shown in FIG. 11B, when the offset amount is 0, the machined other side left tapered tooth surface 121f is machined in a shape close to the designed involute curve. On the other hand, as shown in FIG. 11C, at the offset amount + d, the machined left-side tapered tooth surface 121f is in the right direction (dotted arrow direction) in the drawing, that is, in the clockwise pitch circular direction with respect to the design involut curve. As shown in FIG. 11D, the left tapered tooth surface 121f on the other side processed in the offset amount −d is in the left direction (dotted arrow direction) in the drawing with respect to the design involut curve. That is, it is processed in a shape deviated in the counterclockwise pitch circular direction. Therefore, the shape of the left tapered tooth surface 121f on the other side can be shifted in the pitch circular direction by changing the position of the machining tool 42 in the tool axis L direction.

Further, for example, as shown in FIG. 12A, when the crossing angle of the machining tool 42 is an angle of φf, φb, or φc, the other side left tapered tooth surface 121f is machined. The magnitude relationship of each angle is φf> φb> φc. As a result, the processing states of the left tapered tooth surface 121f on the other side are shown in FIGS. 12B, 12C, and 12D.

As shown in FIG. 12B, at the crossing angle φf, the machined other side left tapered tooth surface 121f is machined in a shape close to the designed involute curve. On the other hand, as shown in FIG. 12C, at the crossing angle φb, the width of the tooth tip of the processed other side left tapered tooth surface 121f narrows in the pitch circular direction (solid arrow direction) with respect to the design involute curve. The width of the tooth root is machined in a shape that expands in the pitch circular direction (solid arrow direction), and as shown in FIG. 12D, at the crossing angle φc, the machined left tapered tooth surface 121f on the other side is a design involut curve. On the other hand, the width of the tooth tip is further narrowed in the pitch circle direction (solid line arrow direction), and the width of the tooth root is further widened in the pitch circle direction (solid line arrow direction). Therefore, the shape of the left tapered tooth surface 121f on the other side can change the width of the tooth tip in the pitch circle direction and the width of the tooth root in the pitch circle direction by changing the crossing angle of the machining tool 42.

Further, for example, as shown in FIG. 13A, the axial position of the machining tool 42, that is, the intersection P between the tool end surface 42M of the machining tool 42 and the tool axis L is located on the rotation axis Lw of the sleeve 115 ( The other side when the offset amount is 0) and the intersection angle of the machining tool 42 is φf, and when the machining tool 42 is offset by a distance + d in the tool axis L direction (offset amount + d) and the intersection angle is φb. The left tapered tooth surface 121f was machined. As a result, the processed state of the left tapered tooth surface 121f on the other side is shown in FIGS. 13B and 13C.

As shown in FIG. 13B, when the offset amount is 0 and the intersection angle is φf, the machined other side left tapered tooth surface 121f is machined in a shape close to the designed involute curve. On the other hand, as shown in FIG. 13C, when the offset amount + d and the intersection angle φb, the machined other side left tapered tooth surface 121f is in the right direction (dotted arrow direction) in the drawing, that is, clockwise with respect to the design involut curve. Is processed in a shape that is displaced in the pitch circle direction, the width of the tooth tip is narrowed in the pitch circle direction (solid line arrow direction), and the width of the tooth root is widened in the pitch circle direction (solid line arrow direction). Therefore, the shape of the left tapered tooth surface 121f on the other side is shifted in the pitch circular direction by changing the axial position of the machining tool 42 and the crossing angle of the machining tool 42, and the width in the circumferential direction of the tooth tip and the width of the tooth tip are changed. The width of the tooth base in the pitch circle direction can be changed.

As described above, the machining tool 42 is set in the gear machining apparatus 1 with an offset amount of 0 and an intersection angle of φf, so that the left tapered tooth surface 121f on the other side can be machined with high accuracy. The tool state of the machining tool 42 is set by the tool state calculation unit 103 of the control device 100, and the details of the processing will be described later.

(4. Processing by the tool design department of the control device)
Next, the design process of the first tool 42F by the tool design unit 102 of the control device 100 will be described with reference to FIGS. 2, 8A, 8B, 8C and 8D. The data regarding the gear disengagement prevention portion 120F, that is, the twist angle θf and the tooth streak length ff of the left tapered tooth surface 121f on the other side, the tooth streak length gf and the tooth surface spacing Hf of the left sub tooth surface 121af on the other side, and the right side on the other side. It is assumed that the twist angle θb and the tooth line length fr of the tapered tooth surface 122f, the tooth line length gr and the tooth surface spacing Hr of the right sub tooth surface 122af on the other side are stored in advance in the storage unit 104. Further, data on the first tool 42F, that is, the number of blades Z, the blade edge circle diameter da, the reference circle diameter d, the blade edge ha, the module m, the shift coefficient λ, the pressure angle α, the front pressure angle αt, and the blade edge pressure angle αa. Is pre-stored in the storage unit 104.

The tool design unit 102 of the control device 100 reads the helix angle θf of the left tapered tooth surface 121f on the other side from the storage unit 104 (step S1 in FIG. 2). Then, the tool design unit 102 has the cross angle φf of the machining tool 42 when cutting the other side left tapered tooth surface 121f input by the operator and the helix angle θf of the other side left tapered tooth surface 121f read. The difference from the above is obtained as the helix angle β of the blade streak 42bf of the first tool blade 42af of the first tool 42F (step S2 in FIG. 2).

The tool design unit 102 reads the blade number Z and the like of the first tool 42F from the storage unit 104, and sets the twist angle β of the blade number Z and the like of the first tool 42F and the blade streak 42bf of the obtained first tool blade 42af. Based on this, the blade edge width Sa and the blade thickness Ta of the first tool blade 42af are obtained (step S3 in FIG. 2). Then, the tool design unit 102 reads out the tooth streak length gf of the other side left sub tooth surface 121af from the storage unit 104, and the determined blade edge width Sa of the first tool blade 42af is the tooth streak length of the other side left sub tooth surface 121af. It is determined whether or not it is larger than gf (step S4 in FIG. 2).

When the blade edge width Sa of the obtained first tool blade 42af is equal to or less than the tooth streak length gf of the left sub tooth surface 121af on the other side, the tool design unit 102 returns to step S2 and repeats the above process. On the other hand, when the blade edge width Sa of the obtained first tool blade 42af becomes larger than the tooth streak length gf of the other side left sub tooth surface 121af, the tooth surface spacing Hf is read out from the storage unit 104, and the obtained first tool blade 42af It is determined whether or not the blade thickness Ta is smaller than the tooth surface spacing Hf on the other side left tapered tooth surface 121f side (step S5 in FIG. 2).

When the blade thickness Ta of the obtained first tool blade 42af is equal to or greater than the tooth surface spacing Hf on the other side left tapered tooth surface 121f side, the tool design unit 102 returns to step S2 and repeats the above process. On the other hand, when the blade thickness Ta of the obtained first tool blade 42af becomes smaller than the tooth surface spacing Hf on the other side left tapered tooth surface 121f side, the tool design unit 102 transfers the other side right tapered tooth surface 122f from the storage unit 104. Read the helix angle θb (step S6 in FIG. 2). Then, the tool design unit 102 determines the difference between the helix angle β of the blade streak 42bf of the first tool blade 42af of the first tool 42F obtained in step S2 and the helix angle θb of the read opposite right tapered tooth surface 122f. , The cross angle φb of the machining tool 42 when cutting the right tapered tooth surface 122f on the other side is obtained (step S7 in FIG. 2).

The tool design unit 102 reads out the tooth streak length gr of the other side right sub tooth surface 122af from the storage unit 104, and the blade edge width Sa of the first tool blade 42af obtained in step S33 is the tooth streak of the other side right sub tooth surface 122af. It is determined whether or not it is larger than the length gr (step S8 in FIG. 2). When the cutting edge width Sa is equal to or less than the tooth streak length gr of the right sub tooth surface 122af on the other side, the tool design unit 102 returns to step S2 and repeats the above process. On the other hand, when the blade edge width Sa becomes larger than the tooth streak length gr of the other side right sub tooth surface 122af, the tooth surface spacing Hr is read out from the storage unit 104, and the blade thickness Ta is the tooth surface spacing on the other side right tapered tooth surface 122f side. It is determined whether or not it is smaller than Hr (step S9 in FIG. 2).

When the blade thickness Ta is equal to or greater than the tooth surface spacing Hr on the other side right tapered tooth surface 122f side, the tool design unit 102 returns to step S2 and repeats the above process. On the other hand, when the blade thickness Ta becomes smaller than the tooth surface spacing Hr on the other side right tapered tooth surface 122f side, the shape of the first tool 42F is based on the obtained helix angle β of the blade streak 42bf of the first tool blade 42af. (Step S10 in FIG. 2), the determined shape data of the first tool 42F is stored in the storage unit 104 (step S11 in FIG. 2), and all the processes are completed. As described above, the first tool 42F having the best first tool blade 42af (second tool 42B having the second tool blade 42ab) is designed.

(5. Processing by the tool state calculation unit of the control device)
Next, the processing by the tool state calculation unit 103 of the control device 100 will be described with reference to FIG. Since this process is a simulation process for calculating the locus of the first tool blade 42af of the first tool 42F based on a known gear creation theory, actual machining is not required and cost reduction can be achieved. ..

The tool state calculation unit 103 of the control device 100 reads the tool state such as the axial position of the machining tool 42 when cutting the other side left tapered tooth surface 121f from the storage unit 104 (step S11 in FIG. 3). It is stored in the storage unit 104 that the number of simulations n is the first time (step S12 in FIG. 3), and the machining tool 42 is set to the read tool state (step S13 in FIG. 3).

Then, the tool state calculation unit 103 obtains the tool locus when processing the other side left tapered tooth surface 121f based on the shape data of the first tool 42F read from the storage unit 104 (step S14 in FIG. 3). The shape of the left tapered tooth surface 121f on the other side after processing is obtained (step S15 in FIG. 3). Then, the tool state calculation unit 103 compares the shape of the left tapered tooth surface 121f on the other side after the obtained machining with the shape of the left tapered tooth surface 121f on the other side in design, obtains a shape error, and stores the storage unit 104. (Step S16 in FIG. 3), and 1 is added to the number of simulations n (step S17 in FIG. 3).

Then, the tool state calculation unit 103 determines whether or not the simulation number n has reached the preset number nn (step S18 in FIG. 3), and if the simulation number n has not reached the set number nn, the machining is performed. Among the tool states of the tool 42, for example, the axial position of the machining tool 42 is changed (step S19 in FIG. 3), the process returns to step S14, and the above process is repeated. On the other hand, when the number of simulations n reaches the set number of times nn, the tool state calculation unit 103 selects the axial position of the machining tool 42, which is the smallest error among the stored shape errors, and stores it in the storage unit 104. (Step S20 in FIG. 3), and all the processes are completed.

In the above process, a plurality of simulations were performed to select the axial position of the machining tool 42 having the minimum error, but the allowable shape error was set in advance and calculated in step S16. The axial position of the machining tool 42 when the shape error is equal to or less than the allowable shape error may be selected. Further, in step S19, instead of changing the axial position of the machining tool 42, the crossing angle of the machining tool 42 is changed, the axial position of the machining tool 42 is changed, or the crossing angle is changed. , Arbitrary combination of axial position and axial position may be changed.

(6. Processing by the processing control unit of the control device)
Next, the processing by the machining control unit 101 of the control device 100 will be described with reference to FIGS. 4A and 4B. Here, the operator manufactures the first tool 42F and the second tool 42B based on the shape data of the first tool 42F and the second tool 42B designed by the tool design unit 102, and assembles them to the tool holder 45. It is assumed that the gear processing device 1 is stored in the tool stocker of the automatic tool changer. Further, it is assumed that the sleeve 115 is attached to the workpiece holder 80 of the gear processing apparatus 1 and the internal teeth 115a are formed by turning or broaching.

The machining control unit 101 of the control device 100 replaces the machining tool in the previous machining step (turning, broaching, etc.) with the machining tool 42 by the automatic tool changer (step S21 in FIG. 4A). Then, the machining control unit 101 sets the machining tool 42 and the sleeve 115 so as to be in the tool state of the machining tool 42 when machining the left tapered tooth surface 121f on the other side of the sleeve 115 obtained by the tool state calculation unit 103. Arrange (step S22 in FIG. 4A). Specifically, as shown in FIG. 8B, the first tool 42F of the machining tool 42 held by the rotary spindle 40 faces the sleeve 115 held by the workpiece holder 80, and the machining tool 42 Is arranged so as to be the axial position (for example, offset amount 0) and the cross angle φf of the machining tool 42 when forming the other side left tapered tooth surface 121f obtained by the tool state calculation unit 103.

The machining control unit 101 feeds the machining tool 42 toward the sleeve 115 in the direction of the rotation axis Lw of the sleeve 115 while rotating the machining tool 42 in synchronization with the sleeve 115, and cuts the internal teeth 115a. The other side left tapered tooth surface 121f including the other side left sub tooth surface 121af is formed on the tooth 115a (step S23 in FIG. 4A).

That is, as shown in FIGS. 14A-14C, the first tool 42F includes the other side left sub tooth surface 121af in the internal tooth 115a in one or a plurality of cutting operations in the rotation axis Lw direction of the sleeve 115. The other side left tapered tooth surface 121f is formed. At this time, the first tool 42F needs to perform a feed operation and a return operation in the direction opposite to the feed operation, and as shown in FIG. 14C, an inertial force acts on this reversal operation. Therefore, the feeding operation of the first tool 42F is at a point Q which is shorter than the tooth streak length ff of the other side left tapered tooth surface 121f which can form the other side left tapered tooth surface 121f including the other side left sub tooth surface 121af. It ends and shifts to the return operation. This feed end point Q can be obtained by measuring with a sensor or the like, but if the feed amount accuracy is sufficient for the required machining accuracy, it can be adjusted by the feed amount without measurement. can. That is, by adjusting the feed amount and the like so that the processing can be performed up to the point Q and performing the cutting processing, the processing can be performed with high accuracy.

Then, when the cutting of the left tapered tooth surface 121f on the other side is completed (step S24 in FIG. 4A), the machining control unit 101 processes the right tapered tooth surface 122f on the other side of the sleeve 115 obtained by the tool state calculation unit 103. The machining tool 42 and the sleeve 115 are arranged so as to be in the tool state of the machining tool 42 (step S25 in FIG. 4A). Specifically, as shown in FIG. 8D, the first tool 42F of the machining tool 42 held by the rotary spindle 40 faces the sleeve 115 held by the workpiece holder 80, and the machining tool 42 Is arranged so as to be the axial position (for example, offset amount 0) and the cross angle φb of the machining tool 42 when forming the other side right tapered tooth surface 122f obtained by the tool state calculation unit 103.

The machining control unit 101 feeds the machining tool 42 toward the sleeve 115 in the direction of the rotation axis Lw of the sleeve 115 while rotating the machining tool 42 in synchronization with the sleeve 115, and cuts the internal teeth 115a. The other side right tapered tooth surface 122f including the other side right sub tooth surface 122af is cut and formed on the tooth 115a (step S26 in FIG. 4A).

Then, when the machining of the right tapered tooth surface 122f on the other side is completed (step S27 in FIG. 4A), the machining control unit 101 determines whether or not the machining of the gear disengagement prevention portion 120B on one side of the sleeve 115 is completed. (Step S28 in FIG. 4A). Then, when the processing control unit 101 determines that the processing of the gear disengagement prevention unit 120B on one side of the sleeve 115 is completed, all the processing is completed. On the other hand, when the machining control unit 101 determines that the machining of the gear disengagement prevention portion 120B on one side of the sleeve 115 has not been completed, the machining control unit 101 feeds the machining tool 42 in the rotation axis Lw direction of the sleeve 115 to operate the sleeve 115. It passes through the inner circumference (step S29 in FIG. 4A) and proceeds to step S30 in FIG. 4B.

Then, the machining control unit 101 sets the machining tool 42 and the sleeve 115 so as to be in the tool state of the machining tool 42 when machining the one-side right tapered tooth surface 121b of the sleeve 115 obtained by the tool state calculation unit 103. Arrange (step S30 in FIG. 4B). Specifically, as shown in FIG. 15A, the second tool 42B of the machining tool 42 held by the rotary spindle 40 faces the sleeve 115 held by the workpiece holder 80, and the machining tool 42 Is arranged so as to be the axial position (for example, offset amount 0) and the cross angle φf of the machining tool 42 when forming the one-side right tapered tooth surface 121b obtained by the tool state calculation unit 103.

The machining control unit 101 rotates the machining tool 42 in synchronization with the sleeve 115 and returns the second tool 42B side toward the sleeve 115 in the direction of the rotation axis Lw of the sleeve 115 to cut the internal teeth 115a. A one-sided right tapered tooth surface 121b including a one-sided right sub-tooth surface 121ab is formed on the tooth 115a (step S31 in FIG. 4B).

That is, as shown in FIGS. 16A to 16C, the second tool 42B includes the one-side right sub-tooth surface 121ab in the internal tooth 115a in one or a plurality of cutting operations in the rotation axis Lw direction of the sleeve 115. One side right tapered tooth surface 121b is formed. At this time, the second tool 42B needs to perform a return operation and a feed operation, and as shown in FIG. 16C, an inertial force acts on this reversal operation. Therefore, the return operation of the second tool 42B is performed at a point R which is shorter than the tooth streak length ff of the one-side right tapered tooth surface 121b capable of forming the one-side right tapered tooth surface 121b including the one-side right sub tooth surface 121ab. It ends and shifts to the feed operation. This return end point R can be obtained by measuring with a sensor or the like, but if the feed amount accuracy is sufficient for the required machining accuracy, it can be adjusted by the feed amount without measurement. can. That is, by adjusting the feed amount and the like so as to be able to process up to the point R and performing the cutting process, it is possible to process with high accuracy.

Then, when the cutting of the one-side right tapered tooth surface 121b is completed (step S32 in FIG. 4B), the machining control unit 101 processes the one-side left tapered tooth surface 122b of the sleeve 115 obtained by the tool state calculation unit 103. The machining tool 42 and the sleeve 115 are arranged so as to be in the tool state of the machining tool 42 (step S33 in FIG. 4B). Specifically, as shown in FIG. 15B, the second tool 42B of the machining tool 42 held by the rotary spindle 40 faces the sleeve 115 held by the workpiece holder 80, and the machining tool 42 Is arranged so as to be the axial position (for example, offset amount 0) and the cross angle φb of the machining tool 42 when forming the one-side left tapered tooth surface 122b obtained by the tool state calculation unit 103.

The machining control unit 101 rotates the machining tool 42 in synchronization with the sleeve 115 and returns the second tool 42B side toward the sleeve 115 in the direction of the rotation axis Lw of the sleeve 115 to cut the internal teeth 115a. A one-sided left tapered tooth surface 122b including a one-sided left sub-tooth surface 122a is cut and formed on the tooth 115a (step S34 in FIG. 4B). Then, when the machining of the left tapered tooth surface 122b on one side is completed (step S35 in FIG. 4B), the machining control unit 101 determines whether or not the machining of the gear disengagement prevention portion 120F on the other side of the sleeve 115 is completed. (Step S36 in FIG. 4B). Then, when the machining control unit 101 determines that the machining of the gear disengagement prevention portion 120F on the other side of the sleeve 115 has not been completed, the machining control unit 101 feeds the machining tool 42 in the rotation axis Lw direction of the sleeve 115 to operate the sleeve 115. It passes through the inner circumference (step S37 in FIG. 4B) and proceeds to step S22 in FIG. 4A. On the other hand, when the processing control unit 101 determines that the processing of the gear disengagement prevention unit 120F on the other side of the sleeve 115 is completed, all the processing is completed.

(7. Others)
In the above example, the first tool 42F and the second tool 42B are formed separately, and the collar 44 is sandwiched between the first tool 42F and the second tool 42B to form the machining tool 42. A machining tool 42 of the same material having a 42af and a second tool blade 42ab may be used. This facilitates assembly of the machining tool 42 to the tool holder 45.

Further, in the above example, the case where the gear disengagement prevention portions 120F and 120B are formed on the processed internal teeth 115a of the sleeve 115 by cutting with the machining tool 42 has been described. However, the gear disengagement prevention portions 120F and 120B are rough-processed by rolling to leave a finishing allowance for the already machined internal teeth 115a of the sleeve 115, and then the finishing allowance is cut by the machining tool 42 for finishing. It may be formed by doing. Therefore, the machining tool 42 can cut the gear disengagement prevention portions 120F and 120B with high accuracy.

Further, in the above example, the case where the internal teeth 115a of the sleeve 115 are formed by broaching, gear shaper processing, or the like has been described, but the sleeve is formed by cutting with a processing tool and a processing tool 42 capable of forming the internal teeth 115a. The internal teeth 115a of the 115 and the gear disengagement prevention portions 120F and 120B may all be formed. Further, although the case of processing the internal tooth has been described, the external tooth can be processed in the same manner. Further, although the sleeve 115 of the synchromesh mechanism 110 is used as the workpiece, it may be a cylindrical or disk-shaped workpiece, and a plurality of tooth surfaces may be formed on either one or both of the inner circumference (inner tooth) and the outer circumference (outer tooth). (Multiple different tooth streaks and tooth profiles (teeth tips, tooth roots)) can be processed in the same manner. In addition, continuously changing tooth streaks and tooth profiles (teeth tips, tooth roots) such as crowning and relieving can be processed in the same manner.

Further, in the above example, the gear processing device 1 which is a 5-axis machining center enables the sleeve 115 to be swiveled around the A axis. On the other hand, the 5-axis machining center may be configured as a vertical machining center so that the machining tool 42 can turn A-axis. Further, although the case where the present invention is applied to a machining center has been described, it can be similarly applied to a dedicated machine for gear processing.

(Effect of embodiment)
The gear machining apparatus 1 of the present embodiment uses a machining tool 42 having a rotary axis L inclined with respect to the rotary axis Lw of the workpiece (sleeve 115), and machining while rotating the machining tool 42 in synchronization with the workpiece 115. A gear processing device 1 for processing a gear by relatively moving in the L direction of the rotation axis of the object 115, wherein the left side surface 115A and the right side surface 115B (side surface) of the gear teeth 115a are the left tooth surface 115b and the right side. A plurality of other side left tapered tooth surfaces 121f, one side left tapered tooth surface 122b, the other side right tapered tooth surface 122f, and one side right tapered tooth surface 121b having different twist angles with respect to the tooth surface 115c (main tooth surface) ( Subordinate tooth surfaces) are provided on one side and the other side of the work piece 115 in the rotation axis Lw direction on the left side surface 115A and the right side surface 115B (side surface), respectively, and the rake surface 42cf of the processing tool 42 is used for processing. The tool 42 has a first tool blade 42af facing one side in the rotation axis L direction of the tool 42, and a second tool blade 42ab whose rake surface 42cc faces the other side in the rotation axis L direction of the machining tool 42.

Then, the first tool blade 42af moves the machining tool 42 relatively to the other side in the rotation axis Lw direction of the workpiece 115, and is provided on the other side of the workpiece 115 in the rotation axis Lw direction. The second tool blade 42ab is used when machining the left tapered tooth surface 121f and the other right tapered tooth surface 122f (subordinate tooth surface), and the second tool blade 42ab is used to move the machining tool 42 to one of the rotation axis Lw directions of the workpiece 115. When the one-side left tapered tooth surface 122b and the one-side right tapered tooth surface 121b (subordinate tooth surface) provided on one side of the rotation axis Lw direction of the workpiece 115 are machined by moving them relatively to the side. Used for.

As a result, the gear machining apparatus 1 has a left tapered tooth surface 121f on the other side, a right tapered tooth surface 122f on the other side, and a right tapered tooth on the one side, which have different helix angles on both end faces of the workpiece 115 with one machining tool 42. Since the surface 121b and the one-side left tapered tooth surface 122b (multiple tooth surfaces) can be formed, there is no need to replace or align the two machining tools that were conventionally required, and the machining efficiency can be improved and machining can be performed. The accuracy can be improved.

Further, the left side surface 115A and the right side surface 115B (side surface) of the gear teeth 115a are the rotation axes of the workpiece 115 on the main left tooth surface 115b (first tooth surface) and left tooth surface 115b (first tooth surface). Provided on one side in the rotation axis Lw direction of the workpiece 115 on the secondary left tapered tooth surface 121f (second tooth surface) and the left tooth surface 115b (first tooth surface) provided on the other side in the Lw direction. It has a one-sided left tapered tooth surface 122b (third tooth surface), and the blade streak 42bf of the first tool blade 42af is on the other side with respect to the pre-processed left tooth surface 115b (first tooth surface). The twist angle θf of the left tapered tooth surface 121f (second tooth surface) on the other side, the rotation axis Lw of the workpiece 115, and the rotation of the machining tool 42 so that the left tapered tooth surface 121f (second tooth surface) can be machined. It has a twist angle β set based on the crossing angle φf with the axis L, and the blade streak 42bb of the second tool blade 42ab is on one side left with respect to the pre-machined left tooth surface 115b (first tooth surface). The twist angle θb of the left tapered tooth surface 122b (third tooth surface) on one side, the rotation axis Lw of the workpiece 115, and the rotation axis of the machining tool 42 so that the tapered tooth surface 122b (third tooth surface) can be machined. It has a twist angle β set based on the intersection angle φb with L.

As a result, the first tool blade 42af does not interfere with the tooth 115a adjacent to the left tooth surface 115b (first tooth surface) to be machined when the other side left tapered tooth surface 121f (second tooth surface) is machined. The second tool blade 42ab can be designed into a shape, and the second tool blade 42ab and the tooth 115a adjacent to the left tooth surface 115b (first tooth surface) to be machined when machining the one-side left tapered tooth surface 122b (third tooth surface). It can be designed in a shape that does not interfere.

Further, the left side surface 115A (one side surface) of the tooth 115a of the gear is the rotation axis Lw of the workpiece 115 on the main left tooth surface 115b (first tooth surface) and left tooth surface 115b (first tooth surface). It is provided on the other side in the rotation axis Lw direction of the workpiece 115 on the secondary left tapered tooth surface 121f (second tooth surface) and the left tooth surface 115b (first tooth surface) provided on one side in the direction. It has a secondary left tapered tooth surface 122b (third tooth surface), and the right side surface 115B (the other side surface) of the tooth of the gear is the main right tooth surface 115c (fourth tooth surface) and right. Subordinate one-sided right tapered tooth surface 121b (fifth tooth surface) and right tooth surface 115c (fourth tooth) provided on one side of the rotation axis Lw direction of the workpiece 115 on the tooth surface 115c (fourth tooth surface). It has a secondary right tapered tooth surface 122f (sixth tooth surface) provided on the other side of the workpiece 115 in the rotation axis Lw direction.

Then, the blade streak 42bf on one side of the first tool blade 42af can process the left tapered tooth surface 121f (second tooth surface) on the other side with respect to the pre-processed left tooth surface 115b (first tooth surface). Based on the twist angle θf of the left tapered tooth surface 121f (second tooth surface) on the other side and the intersection angle φf for the second tooth surface 121f between the rotation axis Lw of the workpiece 115 and the rotation axis L of the machining tool 42. The blade streak 42bf on the other side of the first tool blade 42af has a twist angle β equal to the twist angle β of the blade streak 42bf on one side of the first tool blade 42af. However, the blade streak 42bb on one side of the second tool blade 42ab can process the left tapered tooth surface 122b (third tooth surface) on one side with respect to the pre-machined left tooth surface 115b (first tooth surface). In addition, the twist angle θb of the one-side left tapered tooth surface 122b (third tooth surface), the one-side left tapered tooth surface 122b (third tooth surface) of the rotation axis Lw of the workpiece 115 and the rotation axis L of the machining tool 42. ) Has a twist angle β set based on the cross angle φb, and the blade streak 42bb on the other side of the second tool blade 42ab is the twist angle β of the blade streak 42bb on one side of the second tool blade 42ab. It has a twist angle β of the same angle.

Then, when the machining tool 42 processes the left tapered tooth surface 121f (second tooth surface) on the other side with the first tool blade 42af with respect to the left tooth surface 115b (first tooth surface) machined in advance, the other side The crossing angle φf for the left tapered tooth surface 121f (second tooth surface) is set, and the other side right tapered tooth surface 122f (with the first tool blade 42af) with respect to the pre-processed right tooth surface 115c (fourth tooth surface). The other side obtained based on the twist angle θb of the right tapered tooth surface 122f (sixth tooth surface) on the other side and the twist angle β of the blade streak 42bf on the other side of the first tool blade 42af when machining the sixth tooth surface). The crossing angle φb for the side right tapered tooth surface 122f (sixth tooth surface) is set, and the machining tool 42 is one with the second tool blade 42ab with respect to the premachined left tooth surface 115b (first tooth surface). When processing the side left tapered tooth surface 122b (third tooth surface), the crossing angle φb for the one side left tapered tooth surface 122b (third tooth surface) is set and the right tooth surface 115c (fourth tooth surface) processed in advance is set. When the one-side right tapered tooth surface 121b (fifth tooth surface) is machined with respect to the tooth surface) with the second tool blade 42ab, the twist angle θf of the one-side right tapered tooth surface 121b (fifth tooth surface) and the second tool The crossing angle φf for the one-side right tapered tooth surface 121b (fifth tooth surface) obtained based on the twist angle β of the blade streak 42bb on the other side of the blade 42ab is set.

As a result, the first tool blade 42af does not interfere with the tooth 115a adjacent to the left tooth surface 115b (first tooth surface) to be machined when the other side left tapered tooth surface 121f (second tooth surface) is machined. It can be designed into a shape and can be designed so as not to interfere with the tooth 115a adjacent to the right tooth surface 115c (fourth tooth surface) to be machined when the other side right tapered tooth surface 122f (sixth tooth surface) is machined. .. The second tool blade 42ab is designed so as not to interfere with the tooth 115a adjacent to the left tooth surface 115b (first tooth surface) to be machined when machining the one-side left tapered tooth surface 122b (third tooth surface). At the same time, when processing the one-side right tapered tooth surface 121b (fifth tooth surface), the shape can be designed so as not to interfere with the tooth 115a adjacent to the right tooth surface 115c (fourth tooth surface) to be processed.

The gear is the sleeve 115 of the synchromesh mechanism 110, and the secondary tooth surface is the left tapered tooth surface 121f on the other side and the left on the one side of the gear disengagement prevention portions 120F and 120B provided on the inner peripheral teeth of the sleeve 115. The tapered tooth surface 122b, the other side right tapered tooth surface 122f, and the one side right tapered tooth surface 121b (tooth surface). As a result, the other side left tapered tooth surface 121f, the one side left tapered tooth surface 122b, the other side right tapered tooth surface 122f, and the one side right tapered tooth surface 121b (tooth surface) constituting the gear disengagement prevention portions 120F and 120B are formed. Since the machining accuracy is improved by cutting, it is possible to surely prevent the gear from coming off.

Further, since the blade streaks 42bf of the first tool blade 42af and the blade streaks 42bb of the second tool blade 42ab have the same twist angle β, the tool cost can be reduced. Further, it is possible to form tooth surfaces having different helix angles only by changing the intersection angle of the machining tool 42.

Further, it is a gear processing method for cutting a gear with a processing tool 42 having a rotation axis L inclined with respect to the rotation axis Lw of the work piece 115, and the left side surface 115A and the right side surface 115B (side surface) of the gear teeth are , Left tooth surface 115b, a plurality of other side left tapered tooth surfaces 121f with different twist angles with respect to the right tooth surface 115c (main tooth surface), one side left tapered tooth surface 122b, the other side right tapered tooth surface 122f, one side. The side right tapered tooth surface 121b (subordinate tooth surface) is provided on one side and the other side of the gear rotation axis Lw direction on the left side surface 115A and the right side surface 115B (side surface), respectively, and the machining tool 42 is a rake. The surface 42cf has a first tool blade 42af facing one side in the rotation axis L direction of the machining tool 42, and a rake surface 42cc has a second tool blade 42ab facing the other side in the rotation axis L direction of the machining tool 42. ..

Then, in the gear machining method, the machining tool 42 is rotated in synchronization with the workpiece 115 while being relatively moved in the rotation axis Lw direction on the other side of the workpiece 115 in the rotation axis Lw direction to move the workpiece 115 relative to the rotation axis Lw direction. The first step of machining the other side left tapered tooth surface 121f and the other side right tapered tooth surface 122f (subordinate tooth surface) provided on the other side in the rotation axis Lw direction with the first tool blade 42af, and the machining tool. While rotating the 42 in synchronization with the work piece 115, the work piece 115 is moved relative to the rotation axis Lw direction on one side in the rotation axis Lw direction, and is provided on one side of the work piece 115 in the rotation axis Lw direction. A second step of machining the one-side left tapered tooth surface 122b and the one-side right tapered tooth surface 121b (subordinate tooth surface) with the second tool blade 42ab is provided. As a result, the same effect as that of the gear processing apparatus 1 described above can be obtained.

1: Gear machining equipment, 42: Machining tool, 42F: First tool, 42B: Second tool, 42af: First tool blade, 42ab: Second tool blade, 42bf, 42bb: Blade streak, 100: Control device, 101: Machining control unit, 102: Tool design unit, 103: Tool state calculation unit, 104: Storage unit, 115: Sleeve (workpiece), 115a: Teeth, 115A: Left side surface, 115B: Right side surface, 115b: Left tooth Surface (main tooth surface, first tooth surface), 115c: Right tooth surface (main tooth surface, fourth tooth surface), 121f: Opposite side left tapered tooth surface (subordinate tooth surface, second tooth surface) Surface), 122f: Right tapered tooth surface on the other side (subordinate tooth surface, sixth tooth surface), 121b: Right tapered tooth surface on one side (subordinate tooth surface, fifth tooth surface), 122b: Left on one side Tapered tooth surface (subordinate tooth surface, third tooth surface), β: twist angle of blade streak, θf, θb: twist angle of tooth surface, φf, φb: cross angle

Claims (6)

A workpiece support device that rotatably supports gears as a workpiece,
Machining tools and
A tool support device that rotatably supports the machining tool,
In order to machine the gear teeth on the workpiece, the machining tool is rotated in synchronization with the workpiece in a state where the rotation axis of the machining tool is tilted with respect to the rotation axis of the workpiece. A control device that controls the relative movement of the workpiece in the direction of the rotation axis, and
It is a gear processing device equipped with
On the side surface of the tooth of the gear, a pair of subordinate tooth surfaces having a different helix angle and a different helix angle from the main tooth surface with respect to the surface on which the main tooth surface has been processed in advance . It is configured to machine on one side and the other side in the direction of the rotation axis of the workpiece , respectively.
The processing tool is
The first tool blade whose rake surface faces one side in the direction of the rotation axis of the machining tool,
A second tool blade whose rake surface faces the other side in the direction of the rotation axis of the machining tool ,
Have,
The control device is
A predetermined crossing angle is set, the machining tool is relatively moved to one side in the rotation axis direction of the workpiece , and the first tool blade is used to move the machining tool to the other side in the rotation axis direction of the workpiece. Controlled to process one of the pair of subordinate tooth surfaces provided on the side,
The machining tool is set to an crossing angle different from the crossing angle when machining one of the pair of subordinate tooth surfaces provided on the other side in the rotation axis direction of the workpiece with the first tool blade. Using the second tool blade, the pair of subordinate tooth surfaces provided on one side in the rotation axis direction of the work piece are moved relative to the other side in the rotation axis direction of the work piece . A gear processing device that controls to process the other . In the gear processing apparatus, on the side surface of the tooth of the gear, the surface in which the first tooth surface, which is the main tooth surface, has been machined in advance , is in the direction of the rotation axis of the workpiece on the first tooth surface. The second tooth surface, which is one of the pair of slave tooth surfaces provided on the other side, and the pair of slave teeth provided on one side of the first tooth surface in the direction of the rotation axis of the workpiece. It is configured to machine the third tooth surface, which is the other side of the surface.
The blade streaks of the first tool blade include the helix angle of the second tooth surface, the rotation axis of the work piece, and the rotation axis so that the second tooth surface can be machined with respect to the first tooth surface that has been machined in advance. It has a helix angle set based on the intersection angle with the rotation axis of the machining tool.
The blade streaks of the second tool blade include the helix angle of the third tooth surface, the rotation axis of the work piece, and the rotation axis so that the third tooth surface can be machined with respect to the first tooth surface that has been machined in advance. It has a helix angle set based on the intersection angle with the rotation axis of the machining tool.
The control device is
Using the first tool blade, the second tooth surface is controlled to be machined.
Using the second tool blade, the third tooth surface is controlled to be machined.
The gear processing apparatus according to claim 1. The gear processing device is
On one side surface of the tooth of the gear, it is provided on the other side of the first tooth surface in the direction of the rotation axis with respect to the surface on which the first tooth surface, which is the main tooth surface, has been machined in advance . The second tooth surface, which is one of the pair of slave tooth surfaces, and the other of the pair of slave tooth surfaces provided on one side of the first tooth surface in the direction of the rotation axis of the workpiece. Configured to machine the third tooth surface,
On the other side surface of the tooth of the gear, it is provided on one side of the fourth tooth surface in the direction of the rotation axis with respect to the surface on which the fourth tooth surface, which is the main tooth surface, has been machined in advance . It is one of the fifth tooth surface which is the other of the pair of slave tooth surfaces and the pair of slave tooth surfaces provided on the other side of the fourth tooth surface in the direction of the rotation axis. Configured to machine the sixth tooth surface,
The blade streaks on one side of the first tool blade are the helix angle of the second tooth surface and the rotation of the workpiece so that the second tooth surface can be machined with respect to the pre-machined first tooth surface. It has a helix angle set based on the dihedral angle of the axis and the rotation axis of the machining tool for the second tooth surface.
The blade streaks on the other side of the first tool blade have a helix angle equal to the helix angle of the hemi of the blade streaks on one side of the first tool blade.
The blade streaks on one side of the second tool blade are the helix angle of the third tooth surface and the rotation of the workpiece so that the third tooth surface can be machined with respect to the pre-machined first tooth surface. It has a helix angle set based on the intersection angle of the axis and the rotation axis of the machining tool for the third tooth surface.
The blade streak on the other side surface of the second tool blade has a twist angle equal to the twist angle of the blade streak on one side surface of the second tool blade.
The control device is
The crossing angle for the second tooth surface is set , and the first tool blade is used to control the second tooth surface to be machined with respect to the pre-machined first tooth surface.
The intersection angle for the sixth tooth surface obtained based on the helix angle of the sixth tooth surface and the helix angle of the blade streak on the other side surface of the first tool blade is set , and the first tool blade is used. The sixth tooth surface is controlled to be machined with respect to the pre-machined fourth tooth surface.
The first tool blade is used to set the cross angle for the third tooth surface different from the cross angle when the second tooth surface is machined with the first tool blade, and the first tool blade is machined in advance. Controlled to process the third tooth surface with respect to the tooth surface,
The crossing angle is different from the crossing angle when the sixth tooth surface is machined with the first tool blade, and the twist angle of the fifth tooth surface and the twist angle of the blade streak on the other side surface of the second tool blade. The crossing angle for the fifth tooth surface obtained based on the above is set , and the second tool blade is used to control the fifth tooth surface to be machined with respect to the pre-machined fourth tooth surface. , The gear processing apparatus according to claim 1. The gear is a sleeve of a synchromesh mechanism.
One of claims 1-3, wherein the gear processing device is configured to process the tooth surface of the gear disengagement prevention portion provided on the inner peripheral tooth of the sleeve as the slave tooth surface. The gear processing device described in. The gear processing apparatus according to any one of claims 1-4, wherein the blade streaks of the first tool blade and the blade streaks of the second tool blade have the same helix angle. In a state where the rotation axis of the machining tool is tilted with respect to the rotation axis of the workpiece, the machining tool is rotated in synchronization with the workpiece while being relatively moved in the direction of the rotation axis of the workpiece. A gear processing method for cutting gear teeth on the work piece .
On the side surface of the tooth of the gear, a pair of subordinate tooth surfaces having a different helix angle and a different helix angle from the main tooth surface with respect to the surface on which the main tooth surface has been processed in advance . The workpiece is processed on one side and the other side in the direction of the rotation axis, respectively.
The processing tool is
The first tool blade whose rake surface faces one side in the direction of the rotation axis of the machining tool,
A second tool blade whose rake surface faces the other side in the direction of the rotation axis of the machining tool ,
Have,
The gear processing method is
The machining tool is set to a predetermined crossing angle, and the machining tool is moved relative to one side in the rotation axis direction of the workpiece while rotating synchronously with the workpiece. The first processing step of processing one of the pair of subordinate tooth surfaces provided on the other side in the rotation axis direction of the work piece,
In the first machining step, the crossing angle is set to be different from the crossing angle when machining one of the pair of slave tooth surfaces provided on the other side in the rotation axis direction of the workpiece with the first tool blade. While rotating the machining tool synchronously with the workpiece , the machining tool is relatively moved to the other side in the rotation axis direction of the workpiece , and the second tool blade is used to move the machining tool in the rotation axis direction of the workpiece. A second processing step of processing the other of the pair of slave tooth surfaces provided on one side,
A gear processing method.

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