面齿轮滚磨刀具设计与修整方法研究
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摘要
面齿轮传动是一种圆柱齿轮与面齿轮相啮合的传动,它在直升机主减速器分扭传动装置中具有良好的应用前景。面齿轮加工技术是面齿轮传动技术研究的基础,开展面齿轮滚磨刀具的设计与修整方法研究是实现面齿轮滚磨齿加工研究的基础,也是面齿轮传动研究中不可缺少的重要环节。本文对面齿轮滚磨刀具设计与修整方法进行了较为全面、深入的研究。本文主要研究内容包括:基蜗杆齿面生成方法研究,基于基蜗杆滚磨齿加工的面齿轮齿面及接触特性分析,基蜗杆齿面奇异点研究,基于基蜗杆的滚磨刀具结构参数设计,基于基蜗杆的蜗杆砂轮修整方法研究,基蜗杆设计与分析软件的开发。
为实现面齿轮的滚磨齿加工,采用包络原理对面齿轮滚磨刀具基蜗杆进行设计,建立刀具基蜗杆的包络坐标系,给出刀具基蜗杆的产形面方程,推导了刀具基蜗杆齿廓的曲面方程并对基蜗杆齿廓进行了可视化仿真;利用基蜗杆齿面作为产形面推导面齿轮齿面方程;分别对面齿轮插齿加工以及基于基蜗杆的滚磨齿加工的接触特性进行了分析,并分别对其接触线和接触点进行了可视化仿真;为避免基蜗杆齿面上的奇异点,推导了基蜗杆齿面的奇异点方程,给出避免基蜗杆曲面奇异点的计算方法,进行了基蜗杆曲面奇异点的实例计算,并分别分析基蜗杆半径、插齿刀模数、齿数、压力角等设计参数对基蜗杆齿面奇异点位置的影响;分别对基于基蜗杆的面齿轮滚刀和蜗杆砂轮进行结构参数设计,并提出面齿轮磨齿加工试验台的设计方案;分别根据单参数包络和双参数包络的方法,提出用两种不同的修整方法实现蜗杆砂轮的修整加工,并设计相应的修整装置方案;利用VB.NET对MATLAB和CATIA的调用,编制基蜗杆设计与分析软件。
A face gear drive is formed by an involute pinion and conjugated face gear. The great advantage of application of face gear drives in helicopter transmissions is possibility of the split of the torque. The manufacturing technology of face gear is the groundwork for technology of face gear drives. There is great significance to develop the research on structure design and dressing method of hobbing or grinding worm for manufacturing face gear. The investigation includes the contents of the methd of generation of base worm, the tooth contact analysis of base worm, the research of singularities of base worm, the structure design of hobbing and grinding worm base on base worm, the dressing methods for gringding worm base on base worm and the computer program developed for creating 3D model and simulating the motion of dressing grinding worm.
In order to produce face gear by a hob or grinding worm, the worm thread surface of hobbing or grinding worm was designed, a coordinates was established to describe the enveloping process of the worm, the equations describing the worm thread surface was presented. Tooth contact analysis is designated for simulation of meshing and contact of face gear tooth surface and involute shaper tooth surface, shaper tooth surface and base worm tooth surface, base worm tooth surface and face gear tooth surface, respectively. Basing on two parameter enveloping process, face gear tooth surface was generated by worm tooth surface. A method for avoidance of singularity of worm tooth surface was presented. A numerical example was performed to calculated singularity point. The influence of the base worm radius, the module of shaper, the teeth number and the pressure angle to the singularity point were analyzed, respectively. The structure parameter of hob and grinding worm based on base worm was designed, respectively. An apparatus for grinding face gear was designed. Using two different dressing tools, two apparatuses and methods for dressing grinding worm were presented, respectively. Programmed worm parametric modeling and analysis software utilizing the secondary-developed function of CATIA and MATLAB based on VB.NET.
为实现面齿轮的滚磨齿加工,采用包络原理对面齿轮滚磨刀具基蜗杆进行设计,建立刀具基蜗杆的包络坐标系,给出刀具基蜗杆的产形面方程,推导了刀具基蜗杆齿廓的曲面方程并对基蜗杆齿廓进行了可视化仿真;利用基蜗杆齿面作为产形面推导面齿轮齿面方程;分别对面齿轮插齿加工以及基于基蜗杆的滚磨齿加工的接触特性进行了分析,并分别对其接触线和接触点进行了可视化仿真;为避免基蜗杆齿面上的奇异点,推导了基蜗杆齿面的奇异点方程,给出避免基蜗杆曲面奇异点的计算方法,进行了基蜗杆曲面奇异点的实例计算,并分别分析基蜗杆半径、插齿刀模数、齿数、压力角等设计参数对基蜗杆齿面奇异点位置的影响;分别对基于基蜗杆的面齿轮滚刀和蜗杆砂轮进行结构参数设计,并提出面齿轮磨齿加工试验台的设计方案;分别根据单参数包络和双参数包络的方法,提出用两种不同的修整方法实现蜗杆砂轮的修整加工,并设计相应的修整装置方案;利用VB.NET对MATLAB和CATIA的调用,编制基蜗杆设计与分析软件。
A face gear drive is formed by an involute pinion and conjugated face gear. The great advantage of application of face gear drives in helicopter transmissions is possibility of the split of the torque. The manufacturing technology of face gear is the groundwork for technology of face gear drives. There is great significance to develop the research on structure design and dressing method of hobbing or grinding worm for manufacturing face gear. The investigation includes the contents of the methd of generation of base worm, the tooth contact analysis of base worm, the research of singularities of base worm, the structure design of hobbing and grinding worm base on base worm, the dressing methods for gringding worm base on base worm and the computer program developed for creating 3D model and simulating the motion of dressing grinding worm.
In order to produce face gear by a hob or grinding worm, the worm thread surface of hobbing or grinding worm was designed, a coordinates was established to describe the enveloping process of the worm, the equations describing the worm thread surface was presented. Tooth contact analysis is designated for simulation of meshing and contact of face gear tooth surface and involute shaper tooth surface, shaper tooth surface and base worm tooth surface, base worm tooth surface and face gear tooth surface, respectively. Basing on two parameter enveloping process, face gear tooth surface was generated by worm tooth surface. A method for avoidance of singularity of worm tooth surface was presented. A numerical example was performed to calculated singularity point. The influence of the base worm radius, the module of shaper, the teeth number and the pressure angle to the singularity point were analyzed, respectively. The structure parameter of hob and grinding worm based on base worm was designed, respectively. An apparatus for grinding face gear was designed. Using two different dressing tools, two apparatuses and methods for dressing grinding worm were presented, respectively. Programmed worm parametric modeling and analysis software utilizing the secondary-developed function of CATIA and MATLAB based on VB.NET.
引文
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[2] Litvin F.L, Egelja A, Tan J, et al. Computerized Design, Generation and Simulation of Meshing of Orthogonal Offset Face Gear Drive with a Spur Involute with Localized Bearing Contact[R]. Mechanism and Machine Theory, 1998, 22(1-2):87-1-2
[3] Lewicki D.G, Handschuh R.F,Sheth G, et al. Evaluation of Carburized and Groung Face Gears[R]. NASA-TM-1999-209188, 1999.
[4] Litvin F. L, Chen Y.D,Heath G,F, et al . Apparatus and Method for Precision Grinding Face Gear[R]. U. S. Patent Number 6,146,253, 2000.
[5] Litvin F. L, Egelja A. Handbook on Face Gear Drive with a Spur Involute Pinion[R]. NASA-CR-2000-209909, 2000.
[6] Heath G, Bossler R. B. Advanced Rotorcraft Transmission Programm-Final Report[R]. NASA-CR-101057, 1993.
[7] Litvin F. L, Alfonso Fuentes, Claudio Zanzi, et al. Face Gear Drive with Spur Involute Pinion: Geometry, Generation by a Worm, Stress Analysis[J]. Computer Method in Applied Mechanics and Engineering, 2002, 191(25-26): 2785-2813.
[8] Litvin F. L, Alfonso Fuentes, Matt Howkins. Design, Generation and TCA of New Type of Asymmetric Face Gear Drive with Modified Geometry[J]. Computer Method in Applied Mechanics and Engineering, 2001, 190(43-44): 5837~5865.
[9] Liou C. H . Effect of Contact Ratio on Spur Gear Dynamic Load with no Tooth Profile Modification, Transactions of ASME[J]. Journal of Mechanical Design, 1996, 118(12) .
[10] Lin H. H, Lee C. W, Oswald F. B, et al. Computerized-aided Design of High-contact Ratio Gears for Minimun Dynamic Load and Stress[R]. NASA-TM-103275, 1990.
[11] Marriplis D, Huston R.L. Computerized Simulation og Gear Tooth Manufacturing Processes[R]. NASA-CR-185200, 1990.
[12] Litvin F.L, Wang J. C, Bossler R. B, et al. Design and Geometry of Face Gear Driver[J]. Transactions of ASME, Journal of Mechanical Design, 1992, 114: 642~647.
[13] Litvin F. L, Wang J. C, Bossler R. B, et al. Application of Face Gear Drives In Helicopter Transmission[R]. NASA-TM-105655, 1992.
[14] Handschud R. F, Lewicki D. G, Bossler R. B. Experimental Testing of Prototype Face Gears for Helicopter Transmissions[R]. NASA-TM-105434, 1992.
[15]李伯民,赵波.现代磨削技术[M].北京:机械工业出版社,2003(6).
[16]赵宁,刘常青.关于面齿轮磨削加工机床的研究[J].机械设计与制造,2007(10):151~1522.
[17]颜克君.硬齿面齿轮技术及特点[J].砖瓦,2007(3):10~13.
[18]朱如鹏,潘升材,高德平.面齿轮传动的研究现状与发展[J].南京航空航天大学学报, 1997.29(3):358~361.
[19] Chung T. D, Chang S. H. The Undercutting and Pointing of Face Gear[J]. Journal of The Chinese Institute of Engineerings,1998, 21(2):181~188.
[20] Lenski J. W. Advance Rotorcraft Transmission Report[R]. NASA-25421, 1993.
[21] Kish J. G. Sikorsky Aircraft Advanced Rotorcraft Transmission Program[R]. NASA-CR-191079, 1993.
[22] Huston R. L. Computational Gearing Mechanics[R], NASA-CR-191127, 1993.
[23] Buckingham E. Analytical Mechanics of Gear[J]. New York, Dover Publications,1949:312~320.
[24]朱如鹏,潘升材,高德平.正交面齿轮传动中齿宽设计的研究[M].机械科学与技术,1999,18(4):566~569.
[25]朱如鹏,潘升材,高德平.面齿轮传动的啮合特性研究[M].南京航空航天大学学报,2000,29(3):357~362.
[26]杨连顺,朱如鹏,曾英.正交面齿轮弯曲应力的分析[M].机械科学与技术,2001,20(5):708~714.
[27]靳广虎,朱如鹏,陆俊华.正交面齿轮齿面温升的研究[M].机械传动,2002,26(3):1~3.
[28]李政民卿,朱如鹏.面齿轮插齿加工中过程包络面和理论齿廓的干涉[M].重庆大学学报:自然科学版,2007(7):55~58.
[29]李政民卿,朱如鹏.面齿轮传动的承载接触分析[M].南京航空航天大学学报,2010(2):219~223.
[30]王延忠,熊巍,张俐等.面齿轮齿面方程及其轮齿接触分析[M].机床与液压,2007(12):7~9.
[31]李永祥,毕晓勤,张军顺等.基于ANSYS的直齿面齿轮的承载接触分析[M].机械科学与技术,2009(7):931~935
[32]郭辉,赵宁,方宗德等.基于接触有限元的面齿轮传动弯曲强度研究[M].航空动力学报,2008(8):1438~1442.
[33]姬存强,魏冰阳,邓效忠等.正交面齿轮的设计与插齿加工试验[M].机械传动,2010(2):58~61.
[34]赵宁,郭辉,方宗德等.面齿轮加工技术发展现状与动态[A],中国航空学会第十四届机械动力传输学术讨论会论文集,无锡,2010:39~44.
[35] Ulrich Kissling , Stefan Beermann. Face Gears: Geometry and Strength[M]. USA:Gear Technology, 2007(1):54~61.
[36] Litvin F. L. 1968. Theory of Gearing, 2nd ed[M]. Nauka, (in Russian).
[37] Sandro Barone, Leonardo Borgianni, Carlo Culla, et al. Digital Simulation Procedures to Create 3D Solid Models of Gear [A],ADM International Coference, Rimini, Ttaly, Sept,5th-7th,2001,pp:D3-53~60.
[38] E.W.Miller. Hob for Generating Crow Gears[P], USA patent 2304586,1942.
[39] http://www.expo21xx.com/link/redirector.php4?url=http://www.crowngear.nl.
[40]《航空制造工程手册》总编委会.航空制造工程手册-齿轮工艺[M].北京:航空工业出版社,1995.
[41] Augustinus F.H. Basstein, Prinsenbeek, Gustaaf A. Uittenbogaart, Method for Crown Gear Grinding by Generation[P]. USA patent 5411431,May ,1995.
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