基于高弯曲承载能力的齿轮加工关键技术研究

KEY TECHNOLOGY RESEARCH OF GEAR MACHINING ON HIGH BENDING LOAD CAPACITY

齿根过渡曲线是影响齿轮弯曲承载能力的重要因素,它由刀具齿顶圆弧共轭形成,因此研究齿轮加工方式及刀具刀顶形状对于提高齿轮弯曲承载能力具有十分重要的意义。针对渐开线圆柱齿轮弯曲承载能力,考虑不同的齿轮加工刀具及齿高系数和变位系数等因素,建立相应的齿根过渡曲线模型,通过折截面法探究齿轮加工方式及刀具刀顶形状对齿轮弯曲承载能力的影响,并通过有限元分析对理论结果进行验证。研究表明:当齿轮基本尺寸不变时,对于不同使用要求,高变位时用齿条型单圆弧刀具加工的齿轮弯曲承载能力高于齿条型双圆弧刀具和齿轮型刀具;角变位且小齿轮变位系数为零时,用齿轮型单圆弧刀具加工的齿轮弯曲承载能力高于齿条型刀具。

Dedendum fillet curve is an important factor that affects gear bending capacity and formed by tool conjugation.Consequently,it has great significance on improving bending capacity that the gear machining and top profile of gear cutter are researched. Given different gear machining,addendum coefficient and modification coefficient,the model of corresponding transition curve was established in order to improve bending load capacity of gear. The effect of gear machining and top profile of gear cutter on bending load capacity was investigated with broken-line section method and theoretical analysis was validated by finite element method. Applying the proposed model to the example gear,under the high modification the gear bending capacity machined by rack cutter with single arc is superior to that machined by rack cutter with double arc and pinion type shaper cutter,when the gear geometrical dimensions remain unchanged; the bending capacity of gear machined by pinion type shaper cutter with single arc is superior to rack cutter under the angular modification with modification coefficient of pinion being zero.