非圆齿轮齿面加工余量匀化工艺研究与实现

Research and Implementation of Tooth Surface Machining Allowance Uniform Distribution Processing Technology of Non-circular Gears

针对非圆齿轮加工中,由齿坯节曲线曲率变化所引起的分次进刀过程中齿面加工余量分布不均的问题,提出一种匀化非圆齿轮齿面加工余量的工艺方法。以非圆齿轮插削工艺为研究对象,基于插齿加工原理,对齿面加工余量分布不均的成因进行了分析;在此基础上建立了非圆齿轮匀化工艺插削联动模型,通过实时调整插刀与齿坯的几何位置关系,实现了非圆齿轮齿面加工余量的匀化;开发了非圆齿轮插齿CAM系统,利用CAM系统对齿面加工余量匀化工艺进行了仿真验证,仿真结果表明,所提工艺方法正确、可行;将匀化工艺集成到自主开发的齿轮加工数控系统中,进行了非圆齿轮插削加工试验,试验结果表明,所提工艺方法能够有效匀化齿面加工余量;对加工出的非圆齿轮齿面进行了三维形貌检测,检测结果表明,所提工艺方法能够显著提高非圆齿轮的加工精度与表面质量。

In order to solve the non-uniform tooth surface machining allowances of non-circular gears caused by the curvature variation of gear blank pitch curve in the multiple cutting cycles of non-circular gear machining, a tooth surface machining allowance uniform distribution processing technology for non-circular gears was proposed. Based on the principles of gear shaping, the shaping processes of non-circular gears were studied, and then the origins of the non-uniform tooth surface machining allowances of non-circular gears were analyzed. An uniform distribution processing technology shaping linkage model of non-circular gears was established, so that the tooth surface machining allowances might be distributed uniformly through the real-time adjustment of the geometric position relationship between the shaper and the gear blank. The non-circular gear shaping CAM system was developed, which was used to simulate the tooth surface machining allowance uniform distribution processing technology for non-circular gears, the simulation results show that the proposed processing technology is correct and feasible. The uniform distribution processing technology was integrated into the self-developed gear CNC system, and the actual shaping experiments of non-circular gears were conducted, the experimental results show that the proposed processing technology may uniformly distribute tooth surface machining allowances effectively. Finally, the 3D profile measurements of non-circular gear tooth surfaces were conducted, the measurement results show that the proposed processing technology may significantly improve the surface quality and machining accuracy of non-circular gears.