The machining principle and realization method for the continuous generative grinding face gear by a worm wheel are introduced. Based on a five-axis linked CNC grinding machine, a new method is presented to deprive th...The machining principle and realization method for the continuous generative grinding face gear by a worm wheel are introduced. Based on a five-axis linked CNC grinding machine, a new method is presented to deprive the equation of face gear error tooth surface by assuming the tool surface as the error surface, where actual tool installation position error is introduced into the equation of virtual shaper cutter. Surface equations and 3-D models for the face gear and the worm wheel involving four kinds of tool installation errors are established. When compared, the face gear tooth surface machined in VERICUT software for simulation based on this new method and the one obtained based on real process(grinding face gear by using a theoretical worm wheel with actual position errors) are found to be coincident, which proves the validity and feasibility of this new method. By using mesh planning for the rotating projection plane of the face gear work tooth surface, the deviation values of the tooth surface and the difference surface are acquired, and the influence of four kinds of errors on the face gear tooth surface is analyzed. Accordingly, this work provides a theoretical reference for assembly craft of worm wheel, improvement of face gear machining accuracy and modification of error tooth surface.展开更多
Worm grinding has been applied to manufacture gears to pursue high accuracy and fine surface finish.When the worm used to grind face gears is manufactured with multi-axis computer numerical control(CNC)machining,the m...Worm grinding has been applied to manufacture gears to pursue high accuracy and fine surface finish.When the worm used to grind face gears is manufactured with multi-axis computer numerical control(CNC)machining,the machining accuracy is usually improved by increasing the number of tool paths with more time cost.Differently,this work proposes a generated method to improve the efficiency by dressing the worm surface with only one path,and a closed-loop manufacturing process is applied to ensure the machining accuracy.According to an advanced geometric analysis,the worm surface is practically approximated as a swept surface generated by a planar curve.Meanwhile,this curve is applied as the profile of a dressing wheel,which is used to dress the worm surface.The practical machining is carried out in a CNC machine tool,which was originally used to grind helical gears.Finally,a closed-loop manufacturing process including machining,measurement,and modification is proposed to compensate the machining errors.The proposed method is validated with simulations and practical experiments.展开更多
In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear,a precision generating hobbing method for face gear with the assembly spherical hob is proposed.Firstly,the evoluti...In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear,a precision generating hobbing method for face gear with the assembly spherical hob is proposed.Firstly,the evolution of the cylindrical gear to spherical hob basic worm is analyzed,then the spherical hob basic worm is designed,thus the basic worm and spiral angle equation of spherical hob are obtained.Secondly,based on the design method of the existing hob,the development method of the assembly spherical hob is analyzed,the cutter tooth and the cutter substrate of the assembly hob are designed,and the whole assembly is finished.Thirdly,based on the need of face gear hobbing,a numerical control machine for gear hobbing is developed,and the equation of the face gear is obtained.Fourth,for reducing the face gear processing errors induced by equivalent installation errors,the error analysis model is established and the impacts of each error on the gear tooth surface are analyzed.Finally,the assembly spherical hob is manufactured and the gear hobbing test is completed.According to the measurement results,the processing parameters of face gear hobbing are modified,and the deviation of tooth surface is significantly reduced.展开更多
Aiming at the issue of the grinding integrity of face-gear with worm wheel, the envelope mathematical model of shaper, worm wheel and face-gear is established based on theories of differential geometry and gear mesh. ...Aiming at the issue of the grinding integrity of face-gear with worm wheel, the envelope mathematical model of shaper, worm wheel and face-gear is established based on theories of differential geometry and gear mesh. The judgment of completely grinding the face-gear with the avoidance of singularities is established, and the mathematical expression to show the reason why singularities appear is derived, through the research on the surface contact area and singularity rules of the worm thread surface. The disadvantage of current face-gear grinding method that only part of the working surface of the face-gear can be covered is analyzed and the influence of coefficient of judgment is studied through changing the design parameters.展开更多
基金Projects(51535012,U1604255)supported by the National Natural Science Foundation of ChinaProject(2016JC2001)supported by the Key Research and Development Project of Hunan Province,China
文摘The machining principle and realization method for the continuous generative grinding face gear by a worm wheel are introduced. Based on a five-axis linked CNC grinding machine, a new method is presented to deprive the equation of face gear error tooth surface by assuming the tool surface as the error surface, where actual tool installation position error is introduced into the equation of virtual shaper cutter. Surface equations and 3-D models for the face gear and the worm wheel involving four kinds of tool installation errors are established. When compared, the face gear tooth surface machined in VERICUT software for simulation based on this new method and the one obtained based on real process(grinding face gear by using a theoretical worm wheel with actual position errors) are found to be coincident, which proves the validity and feasibility of this new method. By using mesh planning for the rotating projection plane of the face gear work tooth surface, the deviation values of the tooth surface and the difference surface are acquired, and the influence of four kinds of errors on the face gear tooth surface is analyzed. Accordingly, this work provides a theoretical reference for assembly craft of worm wheel, improvement of face gear machining accuracy and modification of error tooth surface.
基金Project(2019 YFB 2004700)supported by the National Key R&D Project of ChinaProject(HTL-O-19 K 02)supported by National Key Laboratory of Science and Technology on Helicopter Transmission,Nanjing University of Aeronautics and Astronautics,China。
文摘Worm grinding has been applied to manufacture gears to pursue high accuracy and fine surface finish.When the worm used to grind face gears is manufactured with multi-axis computer numerical control(CNC)machining,the machining accuracy is usually improved by increasing the number of tool paths with more time cost.Differently,this work proposes a generated method to improve the efficiency by dressing the worm surface with only one path,and a closed-loop manufacturing process is applied to ensure the machining accuracy.According to an advanced geometric analysis,the worm surface is practically approximated as a swept surface generated by a planar curve.Meanwhile,this curve is applied as the profile of a dressing wheel,which is used to dress the worm surface.The practical machining is carried out in a CNC machine tool,which was originally used to grind helical gears.Finally,a closed-loop manufacturing process including machining,measurement,and modification is proposed to compensate the machining errors.The proposed method is validated with simulations and practical experiments.
基金Project(9140xx8020212xx) supported by the Advanced Research Foundation,ChinaProject(GZ2018KF003) supported by the State Key Laboratory of Smart Manufacturing for Special Vehicles and Transmission System,China
文摘In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear,a precision generating hobbing method for face gear with the assembly spherical hob is proposed.Firstly,the evolution of the cylindrical gear to spherical hob basic worm is analyzed,then the spherical hob basic worm is designed,thus the basic worm and spiral angle equation of spherical hob are obtained.Secondly,based on the design method of the existing hob,the development method of the assembly spherical hob is analyzed,the cutter tooth and the cutter substrate of the assembly hob are designed,and the whole assembly is finished.Thirdly,based on the need of face gear hobbing,a numerical control machine for gear hobbing is developed,and the equation of the face gear is obtained.Fourth,for reducing the face gear processing errors induced by equivalent installation errors,the error analysis model is established and the impacts of each error on the gear tooth surface are analyzed.Finally,the assembly spherical hob is manufactured and the gear hobbing test is completed.According to the measurement results,the processing parameters of face gear hobbing are modified,and the deviation of tooth surface is significantly reduced.
基金Projects(51275530,51535012) supported by the National Natural Science Foundation of ChinaProject(2011CB706800) supported by the National Basic Research Program of China
文摘Aiming at the issue of the grinding integrity of face-gear with worm wheel, the envelope mathematical model of shaper, worm wheel and face-gear is established based on theories of differential geometry and gear mesh. The judgment of completely grinding the face-gear with the avoidance of singularities is established, and the mathematical expression to show the reason why singularities appear is derived, through the research on the surface contact area and singularity rules of the worm thread surface. The disadvantage of current face-gear grinding method that only part of the working surface of the face-gear can be covered is analyzed and the influence of coefficient of judgment is studied through changing the design parameters.
