JPH1177431A - Gear shaper working method and gear shaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To remarkably improve cutting speed by coating a film of specific composition on the flank of a gear shaping tool, and working under a specific speed without using cutting fluid. SOLUTION: A pinion cutter 4 is coated with a film of composition (TiL(1-x) Alx ) (Ny C(1-y) ) (0.2<=x<=0.9, 0.2<=y<=1.0). Coating of the film is executed at least on the flank of the pinion cutter 4. In a gear shaper, generation of tooth profile is executed by reciprocating the pinion cutter 4 up and down to cut in a work 1, and giving relative rotational motion to the work 1 against the pinion cutter 4. Cutting is executed by dry cut without supplying cutting fluid. An abrasion loss increases as the cutting speed becomes higher, and hence the cutting speed is set to be under 300 m/min. Hereby, the cutting speed can be remarkably improved without using an expensive tool.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a gear shaper machining method and a gear shaper for shaping a gear using a gear shaping tool such as a pinion cutter or a rack cutter having a blade portion made of high-speed tool steel.

[0002]

2. Description of the Related Art FIG. 14 shows a general gear shaper processing method (a gear shaping method). The work 1 is attached to a work attachment 3 on a table 2 of a gear shaping machine (hereinafter, a gear shaper). A pinion cutter 4 as a gear shaping tool is attached to a cutter head 5 of a gear shaper. The material of the pinion cutter 4 is high-speed tool steel.
Processing (creation) of the tooth shape on the work 1 is performed by using the pinion cutter 4
Is reciprocated up and down to cut into the work 1, and further, a relative rotational movement is given to the pinion cutter 4 and the work 1. The tooth profile is sequentially formed on the outer peripheral surface of the work 1. The processing conditions are set so that a predetermined tooth profile is created on the outer periphery of the work 1. During processing, a cutting oil 6 is applied to the cutting portion from the nozzle 7 to lubricate and cool the cutting portion.

[0003]

The above-described general gear shaper processing method has a problem that the gear cutting speed is low and the processing cost is increased. The gear cutting speed is substantially determined by the speed at which the pinion cutter 4 moves up and down (hereinafter, cutting speed), and is usually 40 m / min for rough cutting and 70 m / min for finishing cutting.
min. In addition, the working environment is deteriorated due to the application of the cutting fluid, and there has been a problem that waste liquid treatment of the cutting fluid is required, and the treatment is costly.

[0004] In recent years, a technology for high-speed gear shaper processing using a gear shaping tool made of a cemented carbide has emerged, and the creation of a tooth profile by the gear shaper has been made more efficient. In the case of using a carbide gear shaping tool, the carbide is brittle, so if machining is performed by supplying a cutting oil, heat cracks occur and chipping occurs. For this reason, when a carbide gear shaping tool is used, dry cutting, in which machining is performed without supplying a cutting oil, has become mainstream. Carbide has much higher heat resistance and wear resistance than high-speed tool steel, so there is no problem even if dry cutting is performed.

[0005] As described above, the machining efficiency is increased by using the carbide gear shaping tool, and in this regard, the machining cost can be reduced. However, since a carbide gear shaping tool is very expensive, the cost increases in that aspect, and the total cost is deteriorated even if the machining efficiency is increased. Further, since the carbide is brittle, there is a possibility that a sudden loss may occur. For this reason, at present, carbide gear shaping tools are not widely used.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a gear shaping method using a gear shaper capable of greatly improving a cutting speed without using a carbide gear shaping tool. And

[0007]

According to a first aspect of the present invention, there is provided a gear shaper machining method for forming a tooth profile using a high-speed tool steel gear shaping tool. As a shaving tool, (Ti _(1-x) Al _x ) (N _y C _(1-y) ) However, at least one film having a composition of 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 At least the flank surface is coated and processed at a cutting speed of 300 m / min or less without using a cutting fluid.

In order to achieve the above object, a gear shaper machining method according to the present invention is a gear shaper machining method for forming a tooth profile using a gear shaping tool made of high-speed tool steel. , Substantially (Ti _(1-x) Al _x ) _(1-w) (N _y C _(1-y) ) _w where 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 0.45 ≦ w ≦ 0.55 Characterized in that at least one layer of the above film is coated on at least the flank face, and is processed at a cutting speed of 300 m / min or less without using a cutting oil.

[0009] In order to achieve the above object, a gear shaper machining method according to the present invention is a gear shaper machining method for forming a tooth profile using a gear shaping tool made of high-speed tool steel. And the nitride forming element is M, and (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C _(1-y) ) _w where 0.2 ≦ x ≦ 0.9 0.2 ≦ A film having a composition of y ≦ 1.0 0.1 ≦ z ≦ 0.8 0.7 ≦ (z + x) <1.0 0.45 ≦ w ≦ 0.55, at least one of which is coated on at least a flank, is used, and a cutting speed of 300 m / It is characterized in that it is processed in min or less.

[0010] In the above-mentioned method, air may be blown to the cutting portion to form a tooth mold.

[0011] gear shaper of the present invention for achieving the above object, _{essentially, (Ti (1-x)} Al x) (N y C (1-y)) However, 0.2 ≦ x ≦ 0.9 0.2 ≦ y At least one layer of a film with a composition of ≦ 1.0, a gear shaping tool made of high-speed tool steel coated on at least the flank is attached to the cutter head, an air nozzle that blows air to the cutting part is provided, and without using a cutting oil , Cutting speed 300m / min
In the following, processing is performed by blowing air from an air nozzle.

Further, the gear shaper of the present invention for achieving the above object substantially comprises (Ti _(1-x) Al _x ) _(1-w) (N _y C _(1-y) ) _w At least one layer of a film having a composition of 0.2 ≤ x ≤ 0.9 0.2 ≤ y ≤ 1.0 0.45 ≤ w ≤ 0.55, and a high speed tool steel gear shaping tool coated on at least the flank is attached to the cutter head. Cutting speed without using
It is characterized by processing at 300m / min or less.

Further, the gear shaper of the present invention for achieving the above object has a nitride forming element of M, and substantially comprises (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C _(1-y) ) _w provided that at least one layer of the film having the composition of 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 0.1 ≦ z ≦ 0.8 0.7 ≦ (z + x) <1.0 0.45 ≦ w ≦ 0.55 A high-speed tool steel coated gear shaping tool is attached to the cutter head, and the cutting speed is reduced without using cutting fluid.
It is characterized by processing at 300m / min or less.

In the above-mentioned gear shaper, an air nozzle for blowing air to the cutting portion is provided.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A configuration of a gear shaper for implementing a gear shaper machining method according to the present invention will be described with reference to FIG. FIG. 1 schematically shows a cutting section of a gear shaper for implementing the gear shaper machining method of the present invention.

In FIG. 1, the basic configuration of the gear shaper itself is almost the same as the conventional one. That is, the work 1 is attached to the work attachment 3 on the table 2 of the gear shaper, and the pinion cutter 4 as a gear shaping tool is attached to the cutter head 5 of the gear shaper. The table 2 and the cutter head 5 are relatively rotated by a driving mechanism (not shown). The cutter head 5 is reciprocated up and down.
Further, the cutter head 5 and the table 2 are relatively moved to give a cut. As described above, the basic configuration is the same as that shown in FIG. 11, but a nozzle for supplying a cutting oil is not provided because dry cutting is realized. In the dry-cut processing, no cutting oil is used, so that there is no generation of stains and unusual odors on the floor, and no waste oil treatment is required. Therefore, it is suitable for improving the working environment and the global environment.

As the pinion cutter 4, TiN,
A high-speed tool steel pinion cutter coated with various films such as TiCN and TiAlN is commercially available.In the gear shaper processing method and the gear shaper according to the present invention, a nitride of TiAl and a carbonitride of TiAl are used as the pinion cutter. Use the coated one.

As the pinion cutter 4, by coating a high-speed tool steel pinion cutter with a nitride of TiAl or a carbonitride of TiAl, the temperature of Al in the coating film increases due to the cutting heat, and as a result, The coating film is oxidized to form an oxide film having high wear resistance on the surface of the coating film, and the pinion cutter 4 is hardly worn. Further, the oxide film has an effect of preventing oxidation inside the film, and can keep the adhesion of the coating film strong.

Here, first, as a first embodiment, a single-layer coating of either TiAl nitride or TiAl carbonitride and a pinion cutter coated with at least one material in a multi-layer coating The following is an example in which is used. In other words, (Ti
_(1-x) Al _x ) (N _y C _(1-y) ) (where 0.2 ≦ x
≦ 0.9, 0.2 ≦ y ≦ 1.0) at least one layer coated on the pinion cutter 4 is used. The film may be coated on at least the flank 4a (see FIG. 2) of the pinion cutter 4.

Then, substantially (Ti _(1-x) Al _x ) (N _y C
_(1-y) ) (where 0.2 ≦ x ≦ 0.9, 0.2 ≦ y ≦
(Ti _(1-x) Al _x ) and (N _y C _(1-y) ) in the 1.0) film
Is (Ti _(1-x) Al _x ) :( N _y C _(1-y) ) = 1.1: 0.
From 9 it is between (Ti _(1-x) Al _x ) :( N _y C _(1-y) ) = 0.9: 1.1. That is, (Ti _(1-x) Al _x ) _(1-w) (N _y C
_(1-y) ) _w in w is 0.45 ≦ w ≦ 0.55.

Usually, (Ti _(1-x) Al _x ) and (N _y C _(1-y) )
Is assumed to be 1: 1.
There is no problem even if NC is contained abundantly to strengthen solid solution.

In the gear shaper shown in FIG. 1, the tooth profile is created by reciprocating the pinion cutter 4 up and down to cut into the work 1 in the same manner as in the prior art, and further imparts a relative rotational movement to the pinion cutter 4 and the work 1. This is done by: The tooth profile is sequentially formed on the outer peripheral surface of the work 1. The processing conditions are set so that a predetermined tooth profile is created on the outer periphery of the work 1. Cutting is performed by dry cutting without supplying a cutting fluid.

In the gear shaper machining method, cutting is performed separately into rough cutting and finishing, and usually about 90% of the cutting area is removed by rough cutting. The load on the pinion cutter 4 is very small. Therefore, the wear of the pinion cutter 4 is mainly generated at the time of rough cutting, and how to suppress this wear is a point of high efficiency.

FIG. 3 focuses on the cutting speed at the time of rough cutting.
The relationship between the value of x and the flank wear of a material having the composition of i _(1-x) Al _x ) N is shown. That is, the abscissa indicates the value of x of the material having the composition of (Ti _(1-x) Al _x ) N coated on the pinion cutter 4, and the ordinate indicates the flank wear of the pinion cutter 4 (mm) Is taken. Here, the material of work 1 is SCM435, and the gear to be processed is module 2.
5. The number of teeth is 40, tooth width is 20mm, and helix angle is 20 degrees. The base material of the pinion cutter 4 is high-speed tool steel SKH51, which has 5 teeth.
0, outer diameter 130mm, coating thickness 1.7μm, single layer. Processing conditions other than the cutting speed are a circumferential feed of 3 mm / stroke and a radial feed of 7 μm / stroke. In addition,
Finishing cutting after rough cutting is at a cutting speed of 100 m / min, a circumferential feed of 1 mm / stroke, and a radial feed of 3 μm / stroke.

In FIG. 3, the flank wear of the pinion cutter is measured at various cutting speeds (20 m / min, 30 m / min, 50 m / min, 80
(m / min, 150m / min, 300m / min) is the amount of flank wear after cutting 100 workpieces. As the cutting speed increases, the amount of wear increases, but even at a cutting speed of 300 m / min, it is within the practical level of flank wear. This practical level of flank wear means that the flank wear after cutting 100 pieces of the workpiece under the above conditions is 0.2 mm or less. In addition,
Under the above conditions, when a conventional pinion cutter coated with TiCN is used for cutting by wet cutting using a cutting oil, the flank wear reaches 0.2 mm at a cutting speed of 50 m / min.

Thus, it can be seen that if the pinion cutter 4 having the coating shown in FIG. 3 is used, machining can be performed without using a cutting oil and at a cutting speed six times faster than the conventional one. In this case, the value of x of the coating film is 0.2 ≦ x
≦ 0.9. As the cutting speed decreases, the flank wear decreases, but if the cutting speed is less than 30 m / min, the flank wear hardly changes even when the cutting speed decreases. Therefore,
Considering the processing efficiency, the cutting speed is preferably 30 m / min or more.

Although the life of the pinion cutter is determined by the larger of the flank wear and the crater wear, in the case of the present invention, the crater wear is 1/4 or less of the flank wear, and the life of the pinion cutter is all flank wear. Determined by wear.

In FIG. 3, when x = 0.5, the flank wear is minimized because when x is large, the film is softened, and when x is small, the oxidation resistance of the film is reduced. It is presumed that the minimum value is obtained at x = 0.5 at which both the oxidation resistance is satisfied.

Next, as a second embodiment, a pinion cutter coated with a single layer of (Ti _0.5 Al _0.5 ) (N _y C _{(1- y)} ) or at least one layer of a multilayer coating with (Ti _0.5 Al _0.5 ) (N _y C _(1-y) ) An example using a coated material will be described. The gear shaper processing using this pinion cutter is performed without applying a cutting oil, that is, dry cutting, as described above. Pinion cutter 4
The conditions other than the coating are the same as in the first embodiment. The coating film is a single layer and the thickness is 1.7 μm.

FIG. 4 shows the effect of the second embodiment. FIG.
As shown in the figure, when the cutting speed is 300 m / min and the flank wear is less than the practical wear limit, the coating film composition is 0
2. ≦ y ≦ 1.0. When the cutting speed is 300 m / min or less, the flank wear decreases as the cutting speed decreases. However, if the cutting speed is less than 30 m / min, the flank wear hardly changes. Therefore, it is desirable that the cutting speed is 30 m / min or more in consideration of machining efficiency. It is considered that the reason why the wear resistance decreases as y decreases becomes that oxidation resistance decreases due to an increase in C instead of N.

FIG. 5 shows the results obtained by determining the appropriate film thickness by coating with (Ti _0.5 Al _0.5 ) N. The horizontal axis in FIG. 5 shows the total film thickness. That, (Ti _0.5 Al _0.5) N represents the film thickness if a single layer, all if a multilayer (Ti _0.5 Al
_0.5 ) Indicates the total thickness of the N film. The vertical axis represents the ratio of the flank wear when the flank wear of the pinion cutter 4 in which a single layer of (Ti _0.5 Al _0.5 ) N is coated at a film thickness of 1.7 μm is set to 1.

Looking at the relationship between flank wear and film thickness when a single layer of (Ti _0.5 Al _0.5 ) N is coated,
At μm, the flank wear is about 20% greater than at 1.7 μm, and gradually decreases as the thickness increases, and at 10 μm, the thickness decreases by 20% from 1.7 μm . However, when the film thickness is reduced to 0.3 μm, the flank wear is twice as much as that when the film thickness is 1.7 μm. On the other hand, when the film thickness becomes 11 μm, the film peels off and the wear increases rapidly.

When the coating of (Ti _0.5 Al _0.5 ) N is multilayered, for example, 0.05 μm TiN is added to (Ti _0.5 A
When _0.5 or 10 layers are coated between _l0.5 ) N, slightly higher performance can be obtained than in the case of a single layer as shown in FIG. From the above, the film thickness is 0.5 μm or more.
It is understood that the thickness is preferably 10 μm or less, and it may be a single layer or a multilayer.

FIG. 6 shows the result of examining the influence of circumferential feed among the cutting conditions under the same machine conditions as in the first embodiment. Cutting speed exceeding the practical wear limit,
Shown for each circumferential feed. The cutting conditions of the gear shaper processing method include circumferential feed and radial feed in addition to the cutting speed. Among them, the cutting speed has the largest effect on tool wear, and the circumferential feeding has the second largest effect. However,
The influence of circumferential feed is generally much smaller than the effect of cutting speed.

As shown in FIG. 6, at a circumferential feed of 1 mm / stroke, the practical wear limit is exceeded when the cutting speed exceeds 320 m / min. From this figure, it can be seen that the cutting speed below the practical wear limit is not significantly affected by the circumferential feed, and is approximately 300 m / min over a wide circumferential feed range. The pinion cutter 4 used here is coated with (Ti _0.5 Al _0.5 ) N. Others are the same as the first embodiment except for the circumferential feed. The coating films shown in FIGS. 6 to 9 are single layers, and have a thickness of 1.7 μm.

FIG. 7 shows the cutting speed exceeding the practical wear limit for each material of the work 1. As the material of the workpiece, carburized and hardened alloy steel (hardness H _B 120 to 300), carbon steel (hardness H _B 0.99 to 300), cast iron (hardness H _B 150 to 300
) Was used. In FIG. 7, there is a cutting speed exceeding the practical limit in the range between the circles in each work material. Therefore, even if the workpiece material is changed, if the cutting speed is approximately 300 m / min or less, the material is practical without exceeding the practical wear limit. In addition,
The conditions here are the same as in the first embodiment except for the work material, except that the coating is (Ti _0.5 Al _0.5 ) N.

FIG. 8 shows the cutting speed exceeding the practical wear limit for each base material of various pinion cutters. The base material is SKH51, SKH55, powdered high speed steel (1.3% C-6%
W-5% Mo) and powdered high-speed steel (2.2% C-12% W-2.5% Mo). As can be seen from the figure, even if the base material of the pinion cutter is changed, if the cutting speed is within approximately 300 m / min, it falls below the practical wear limit and becomes practical. In addition,
The conditions here are the same as in the first embodiment, except that the coating is (Ti _0.5 Al _0.5 ) N and the rest is the base material of the pinion cutter.

FIG. 9 shows the relationship between the work module and the cutting speed exceeding the practical wear limit. From this figure, it can be seen that if the cutting speed is approximately 300 m / min or less, it is below the practical wear limit and becomes practical. The conditions here are the same as in the first embodiment, except for the diameter of the pinion cutter and the work module. The diameter of the pinion cutter was (work module / 2.5) × 130 mm. The coating is (Ti _0.5
Al _0.5 ) N.

Next, another example of the film coated on the pinion cutter 4 will be described. As the pinion cutter 4,
Ti doped with a nitride-forming element capable of forming high-quality nitride
One coated with Al nitride or TiAl carbonitride is used. A single-layer coating of either TiAl nitride or TiAl carbonitride to which a nitride-forming element is added, or a pinion cutter coated with at least one material in a multi-layer coating is used.

Here, as the nitride forming elements, Zr (zirconium), Hf (hafnium), Y (yttrium), V (vanadium), Nb (niobium), Ta (tantalum), Si (silicon), Cr (silicon) Chrome), Mo (molybdenum),
W (tungsten), B (boron), Mg (magnesium), Ca (calcium) and Be (beryllium) are applied.

That is, when the nitride-forming element is M,
To (Ti_zAl_xM_(1-zx))_(1-w)(N _yC_(1-y))_wPair of
(However, 0.2 ≦ x ≦ 0.9, 0.2 ≦ y ≦ 1.0, 0.1 ≦
z ≦ 0.8, 0.7 ≦ (z + x) <1.0, 0.45 ≦ w ≦ 0.55
With at least one layer applied to the pinion cutter 4
Is used. In addition, the coating of the film is small
And the flank 4a of the pinion cutter 4 (see FIG. 2).
It just needs to be.

Further, (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y
C _(1-y) ) By defining the range of x in _w to be 0.2 ≦ x ≦ 0.9 and defining the range of y to be 0.2 ≦ y ≦ 1.0, the range of z is the range of 1 minus x. (Z =
1-x). For this reason, TiAl, NC has the same composition range as in the above case where the nitride-forming element M is not added, and substantially the same effects as the results of FIGS. 3 to 9 are obtained. By adding the nitride-forming element M, the nitride-forming element M can replace TiAl and form a high-quality nitride.

Hereinafter, the case where V (vanadium), B (boron) and Zr (zirconium) are applied as the nitride-forming element M will be specifically described with reference to FIGS. FIG. 10 shows the relationship between the cutting speed and the flank wear when V and B are slightly added, and FIG. 11 shows the cutting speed and the flank wear when V, B and Zr are added more than FIG. Is shown.

Here, the material of the work is SCM435, and the gear to be machined is a module 2.5, the number of teeth is 40, the tooth width is 20 mm, and the helix angle is 20 degrees. The base material of the pinion cutter 4 is SKH51, the number of teeth is 50, the outer diameter is 130 mm, and the coating film thickness is 1.7 μm
Is a single layer. The processing conditions are a circumferential feed of 3 mm / stroke and a radial feed of 7 μm / stroke. Finish cutting after rough cutting is performed at a cutting speed of 100 m / min and a circumferential feed of 1
mm / stroke, radial feed 3μm / stroke. In the figure, the flank wear of the pinion cutter 4 is
The amount of flank wear after cutting 100 workpieces at various cutting speeds.

As shown in FIG. 10, (Ti _z Al _x M
_(1-zx) ) _(1-w) (N _y C _(1-y) ) _w , (Ti _0.795 Al
_0.2 V _0.005 ) N, (Ti _0.15 Al _0.845 V _0.005 ) N, (Ti _0.5 Al _0.45
B _0.05) (if coated with at least one layer to the pinion cutter 4 a film of the composition of N _{0. 9} C _0.1), the cutting speed 80 m / min
From the vicinity to the cutting speed of about 400m / min, the flank wear is less than the practical wear limit (0.20mm). Therefore, even when the nitride forming elements V and B are slightly added, the same high-efficiency and low-cost processing as in the case where the nitride forming elements are not added can be realized. still,
Although not shown in the figure, it has been confirmed that the crater abrasion is within the practical wear limit below the cutting speed of 300 m / min or less.

As shown in FIG. 11, (Ti _z Al _x M
_(1-zx) ) _(1-w) (N _y C _(1-y) ) _w , (Ti _0.5 Al
_0.4 V _0.1 ) N, (Ti _0.6 Al _0.2 B _0.2 ) N, (Ti _0.4 Al _0.3 V _0.3 ) (N
_When at least one layer of the composition of ( _0.7 C _0.3 ) and (Ti _0.4 Al _0.3 Zr _0.3 ) (N _0.5 C _0.5 ) is coated on the pinion cutter 4, the cutting speed is from about 80 m / min to about 300 m / min or less. The flank wear is within the tool wear less than the practical wear limit (0.20mm). Therefore, even when V, B, and Zr, which are the nitride-forming elements, are added more than in FIG. 10, the same high-efficiency and low-cost processing as when no nitride-forming element is added can be realized. Although not shown in the figure, the crater wear was also reduced at a cutting speed of 300 m / min.
It has been confirmed that the wear amount is less than the practical wear limit to below the vicinity.

If the amount of the added nitride-forming element exceeds 0.3 as compared with the composition of the TiAl-added element, the film is liable to peel off. Therefore, the amount of the added nitride-forming element depends on the composition of the TiAl-added element. Is preferably 0.3 or less. If the amount of the nitride-forming element exceeds 0.3 (z + x is less than 0.7) as compared with the composition of the TiAl-added element, that is, if the proportion of the nitride-forming element M is too large, the basic characteristics of TiAl are impaired and peeling occurs. Will occur.

Next, the case where the ratio of the metal element (TiAl, the added nitride-forming element) and the non-metal element (N) containing C is changed will be specifically described with reference to FIG. FIG. 12 shows the relationship between the cutting speed and the flank wear when the composition ratio of the metal element and the nonmetal element including C is changed between 0.45 and 0.55. The processing conditions and the like are the same as those shown in FIGS. The coating film is a single layer and the film thickness is 1.
7 μm.

As shown in FIG. 12, (Ti _z Al _x M
_(1-zx) ) _(1-w) (N _y C _(1-y) ) _w , (Ti _0.5 Al
_0.4 V _0.1 ) _0.45 N _0.55 and (Ti _0.5 Al _0.4 V _0.1 ) _0.55 N _{0.45 When} at least one layer is coated on the pinion cutter 4, when there are many metal elements or when there are many non-metal elements including C Cutting speed 80m /
The flank wear is less than the practical wear limit (0.20mm) at a cutting speed of 300m / min or less from around min, and high efficiency and low cost machining can be realized. Although not shown in the figure, the crater wear was also reduced at a cutting speed of 300 m / m.
It has been confirmed that the wear amount is less than the practical wear limit up to around in. Where w is 0.45 ≦ w
The reason for setting ≦ 0.55 is that if w is out of the range of 0.45 ≦ w ≦ 0.55, there is a possibility that peeling of the film or deterioration of the wear resistance of the film may occur.

Incidentally, (Ti _z Al _x M _(1-zx) ) and (N _y
The ratio of C _(1-y) ) _w is assumed to be 1: 1. However, the ratio of non-metallic elements including C to the metal elements Ti, Al and the added nitride-forming element is increased or decreased. There is no problem. Solid solution strengthening can be expected by increasing the amount of nonmetallic elements including C.

As described above, even when a film to which V, B and Zr are added as a nitride forming element M is coated and dry-cut, the wear amount is within the practical wear limit, and V, B and Zr The same high-efficiency and low-cost processing can be realized as when no is added.

FIG. 13 shows a partial configuration of a gear shaper for implementing still another embodiment of the present invention. This apparatus is the same as that shown in FIG. 1 except that an air nozzle 8 for blowing air to the cutting portion is added to the apparatus shown in FIG.

In the conventional method of applying a cutting oil, the generated chips are washed away with the cutting oil, and the chips do not bite between the workpiece and the pinion cutter in the cutting portion, but the cutting oil is not applied. In such a case, biting may occur to damage the work. If air is supplied to the cutting portion during the dry cutting process as in the present embodiment, chips generated in the cutting portion are blown off and removed, so that chips do not bite. It should be noted that when a small amount of cutting oil is put into air and mist-shaped and sprayed on the cutting portion, almost the same effect as in dry cutting can be obtained.

In the above-described embodiment, the pinion cutter has been described as an example of the gear shaping tool, but the present invention can be similarly applied to a rack cutter.

[0055]

According to the gear shaper machining method of the present invention, in a gear shaper machining method for creating a tooth profile using a gear shaping tool made of high-speed tool steel, the gear shaping tool substantially includes: (Ti _(1-x) Al _x ) (N _y C _(1-y) ) where at least one film having a composition of 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 is coated on at least the flank. Since cutting is performed at a cutting speed of 300 m / min or less without using a cutting oil, the cutting speed can be greatly improved without using an expensive tool such as a carbide and a tooth profile can be created. As a result, gear processing with high efficiency and low cost can be realized. In addition, since it is a dry cut, the supply of cutting oil, which was necessary in machining using conventional high-speed tool steel tools, is no longer necessary, and in this respect costs can be reduced and the working environment is improved. You.

Further, according to the gear shaper machining method of the present invention, in the gear shaper machining method of creating a tooth profile using a gear shaping tool made of high-speed tool steel, the gear shaping tool substantially includes: (Ti _(1-x) Al _x ) _(1-w) (N _y C _(1-y) ) _w However, at least one layer having a composition of 0.2 ≤ x ≤ 0.9 0.2 ≤ y ≤ 1.0 0.45 ≤ w ≤ 0.55 With a coating at least on the flank, and cutting at a cutting speed of 300 m / min or less without using a cutting fluid, greatly improving the cutting speed without using expensive tools such as carbide. To create a tooth profile. As a result, gear processing with high efficiency and low cost can be realized. In addition, since it is a dry cut, the supply of cutting oil, which was necessary in machining using conventional high-speed tool steel tools, is no longer necessary, and in this respect costs can be reduced and the working environment is improved. You. In addition, it is expected that solid solution strengthening of the coating film can be expected by adding NC to Ti or Al, which is a metal element, in an equal or larger amount.

According to the gear shaper machining method of the present invention, in the gear shaper machining method for creating a tooth shape using a gear shaping tool made of high-speed tool steel, the gear shaping tool may include a nitride-forming element. And M is substantially (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C _(1-y) ) _w However, 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 0.1 ≦ Using at least one coating of at least one flank with a film having a composition of z ≦ 0.8 0.7 ≦ (z + x) <1.0 0.45 ≦ w ≦ 0.55, and processing at a cutting speed of 300 m / min or less without using a cutting oil. As a result, the cutting speed can be significantly improved without using an expensive tool such as a carbide tool, and a tooth profile can be created. As a result, gear processing with high efficiency and low cost can be realized. In addition, since it is a dry cut, the supply of cutting oil, which was necessary in machining using conventional high-speed tool steel tools, is no longer necessary, and in this respect costs can be reduced and the working environment is improved. You. In addition, it is expected that solid solution strengthening of the coating film can be expected by adding NC to Ti or Al, which is a metal element, in an equal or larger amount.

Further, since a tooth profile is created by blowing air to the cutting portion, a highly efficient and low-cost gear can be created without the occurrence of chip entrapment.

The gear shaper of the present invention substantially comprises a film having a composition of (Ti _(1-x) Al _x ) (N _y C _(1-y) ) where 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0. Attach a gear shaping tool made of high-speed tool steel with at least one layer coated on at least the flank to the cutter head.
Since the machining is performed at a speed of 300 m / min or less, the cutting speed can be greatly improved and a tooth profile can be created without using expensive tools such as carbide. As a result, gear processing with high efficiency and low cost can be realized. In addition, since it is a dry cut, the supply of cutting oil, which was necessary in machining using conventional high-speed tool steel tools, is no longer necessary, and in this respect costs can be reduced and the working environment is improved. You.

In addition, the gear shaper of the present invention substantially comprises (Ti _(1-x) Al _x ) _(1-w) (N _y C _(1-y) ) _w where 0.2 ≦ x ≦ 0.9 0.2 ≦ A gear shaping tool made of high-speed tool steel coated with at least one film having a composition of y ≦ 1.0 0.45 ≦ w ≦ 0.55 on at least the flank is attached to the cutter head.
Since the machining is performed at a speed of 300 m / min or less, the cutting speed can be greatly improved and a tooth profile can be created without using expensive tools such as carbide. As a result, gear processing with high efficiency and low cost can be realized. In addition, since it is a dry cut, the supply of cutting oil, which was necessary in machining using conventional high-speed tool steel tools, is no longer necessary, and in this respect costs can be reduced and the working environment is improved. You. In addition, it is expected that solid solution strengthening of the coating film can be expected by adding NC to Ti or Al, which is a metal element, in an equal or larger amount.

Further, the gear shaper of the present invention has a nitride forming element of M and substantially (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C _(1-y) ) _w However, 0.2 ≤ x ≤ 0.9 0.2 ≤ y ≤ 1.0 0.1 ≤ z ≤ 0.8 0.7 ≤ (z + x) <1.0 0.45 ≤ w ≤ 0.55 High-speed tool steel coated with at least one layer, at least on the flank. Gear cutting tool is attached to the cutter head, and the cutting speed is reduced without using cutting fluid.
Since the machining is performed at a speed of 300 m / min or less, the cutting speed can be greatly improved and a tooth profile can be created without using expensive tools such as carbide. As a result, gear processing with high efficiency and low cost can be realized. In addition, since it is a dry cut, the supply of cutting oil, which was necessary in machining using conventional high-speed tool steel tools, is no longer necessary, and in this respect costs can be reduced and the working environment is improved. You. In addition, it is expected that solid solution strengthening of the coating film can be expected by adding NC to Ti or Al, which is a metal element, in an equal or larger amount.

Further, since an air nozzle for blowing air to the cutting portion is provided, by forming a tooth profile by blowing air to the cutting portion, it is possible to realize a highly efficient and low-cost gear without generating chips. .

[Brief description of the drawings]

FIG. 1 is a schematic configuration diagram of a cutting section of a gear shaper that implements a gear shaper processing method of the present invention.

FIG. 2 is an explanatory diagram of a pinion cutter.

Fig. 3 Coating pinion cutter (Ti _(1-x)
4 is a graph showing the relationship between the value of x in Al _x ) N and the flank wear of the pinion cutter.

Fig. 4 Coating on pinion cutter (Ti _0.5 Al
_0.5 ) A graph showing the relationship between the value of y in N ( _{NyC (1-y)} ) and the flank wear of the pinion cutter.

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

FIG. 6 is a graph showing the relationship between circumferential feed and cutting speed in the processing method of the present invention.

FIG. 7 is a graph showing a relationship between a workpiece material and a cutting speed in the processing method of the present invention.

FIG. 8 is a graph showing the relationship between the material of the base material of the pinion cutter and the cutting speed in the processing method of the present invention.

FIG. 9 is a graph showing a relationship between a work module and a cutting speed in the processing method of the present invention.

FIG. 10: (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C
_(1-y) is a graph showing the relationship between flank wear and cutting speed when _w is coated.

FIG. 11: (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C
_(1-y) is a graph showing the relationship between flank wear and cutting speed when _w is coated.

FIG. 12: (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C
_(1-y) is a graph showing the relationship between flank wear and cutting speed when _w is coated.

FIG. 13 is a schematic configuration diagram of a cutting portion of a gear shaper that implements the gear shaper processing method of the present invention.

FIG. 14 is a schematic view showing a conventional gear shaper processing method.

[Explanation of symbols]

 Reference Signs List 1 work 2 table 3 work fixture 4 pinion cutter 5 cutter head 8 air nozzle

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Akihide Tsukuya 130 Rokujizo, Ritto-cho, Kurita-gun, Shiga Prefecture Inside Mitsubishi Heavy Industries, Ltd. Kyoto Seiki Co., Ltd.

Claims (8)

[Claims] 1. A gear shaper machining method for creating a tooth profile using a gear shaping tool made of high-speed tool steel, wherein the gear shaping tool is substantially (Ti _(1-x) Al _x ). (N _y C _(1-y) ) where at least one film having a composition of 0.2 ≤ x ≤ 0.9 0.2 ≤ y ≤ 1.0 is coated on at least the flank, and the cutting speed is determined without using a cutting fluid. A gear shaper processing method characterized by processing at a speed of 300 m / min or less. 2. A gear shaper machining method for creating a tooth profile using a gear shaping tool made of high-speed tool steel, wherein the gear shaping tool is substantially (Ti _(1-x) Al _x ). _(1-w) (N _y C _(1-y) ) _w provided that at least one layer of a film having a composition of 0.2 ≤ x ≤ 0.9 0.2 ≤ y ≤ 1.0 0.45 ≤ w ≤ 0.55 is coated on at least the flank. A gear shaper machining method, wherein machining is performed at a cutting speed of 300 m / min or less without using a cutting oil. 3. A gear shaper machining method for creating a tooth profile by using a gear shaping tool made of a high-speed tool steel, wherein the gear shaping tool has a nitride-forming element of M, substantially (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C _(1-y) ) _w where 0.2 ≤ x ≤ 0.9 0.2 ≤ y ≤ 1.0 0.1 ≤ z ≤ 0.8 0.7 ≤ (z + x) <1.0 A gear shaper processing method, wherein at least one layer of a film having a composition of 0.45 ≦ w ≦ 0.55 is coated on at least a flank face, and the processing is performed at a cutting speed of 300 m / min or less without using a cutting oil. 4. The gear shaper processing method according to claim 1, wherein air is blown to the cutting portion. 5. The method according to claim 5, wherein the nitride-forming element is M, and (Ti _(1-x) Al _x ) (N _y C _(1-y) ) wherein 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 A high-speed tool steel gear shaping tool coated with at least one layer of the composition film on at least the flank is attached to the cutter head, and the cutting speed is reduced without using cutting oil.
A gear shaper characterized by being machined at 300m / min or less. 6. (Ti _(1-x) Al _x ) _(1-w) (N _y C _(1-y) ) _w where 0.2 ≦ x ≦ 0.9 0.2 ≦ y ≦ 1.0 0.45 ≦ w A high-speed tool steel gear shaping tool coated with at least one layer of a film with a composition of ≤0.55 on at least the flank is attached to the cutter head, and is processed at a cutting speed of 300 m / min or less without using a cutting fluid. A gear shaper characterized in that: 7. The method according to claim 7, wherein the nitride forming element is M, and (Ti _z Al _x M _(1-zx) ) _(1-w) (N _y C _(1-y) ) _w where 0.2 ≦ x Gear shaping tool made of high-speed tool steel having at least one layer of a film having a composition of ≦ 0.9 0.2 ≦ y ≦ 1.0 0.1 ≦ z ≦ 0.8 0.7 ≦ (z + x) <1.0 0.45 ≦ w ≦ 0.55 The gear shaper is characterized in that it is mounted on a cutter head, and is processed at a cutting speed of 300 m / min or less without using a cutting oil. 8. The gear shaper according to claim 5, further comprising an air nozzle for blowing air to the cutting portion.