螺旋运动及刀具参数对双重螺旋法加工齿面特征的影响规律

Influence Mechanisms Between Helical Motion Velocity Coefficient and Cutter Parameters and Characteristics of Tooth Surface Generated by Duplex Helical Method

双重螺旋法具有高效率、低成本、可干切削等特点是取代'五刀法'的弧齿锥齿轮未来主流加工方法。为了揭示弧齿锥齿轮双重螺旋法的切齿原理,在分析五刀法切齿原理的基础上,研究了刀倾角和齿形角分别在五刀法和双重螺旋法中的不同作用原理,揭示了双重螺旋法切齿原理的本质;分析了螺旋运动在切齿加工中的作用及对齿面几何形貌的影响规律,推导了小轮齿面参考点处的曲率参数计算公式,揭示了螺旋运动系数与参考处曲率的关联规律,并利用轮齿接触分析方法研究了螺旋运动对齿轮副啮合性能的影响规律;利用数值方法研究了刀具齿形角、刀盘半径分别对轮齿接触椭圆长、短半轴半径的影响,建立了刀具参数与轮齿接触特征之间的作用规律。研究工作为优化双重螺旋法的切齿加工参数提供了理论依据。

Duplex helical method will be an advanced and primary manufacturing method of Gleason spiral bevel and hypoid gears and replace five-cut process for its characteristics of higher efficiency, lower cost and power dry cutting. In order to reveal the universal theory of spiral bevel and hypoid gears generated by the duplex helical method, the different working mechanisms of blade angle and tilt angle in the five-cut process and duplex helical method is researched and the major idea in the completing theory is revealed based on the analysis of cutting principle for the five-cut process; In addition, the roles and characteristics of the helical motion are analyzed during machining, the correlation rules between the curvature at the reference points and the helical motion velocity coefficient are revealed by deriving the curvature equations at the reference points of pinion surfaces, and the influence rules between the helical motion velocity coefficient and the meshing performance are discussed by using tooth contact analysis(TCA); Finally, the impacts of blade pressure angle and cutter radius on the major and minor axis semi-diameter of the tooth contact ellipse are studied by using the numerical method, the influence mechanisms between cutter parameters and tooth contact characteristics are established. The research work provides a theoretical basis for optimizing its machining parameters.