螺旋伞齿轮新加工方法及关键技术的研究
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摘要
深入研究了基于产形面的齿面坐标点计算方法和基于B样条插值的齿面坐标点计算方法,并讨论了这两种方法的适用范围。为了解决大批量Gleason制螺旋锥齿轮制造中的热后精整问题,本文提出了将珩齿技术应用于螺旋锥齿轮的硬齿面加工中,并提出了珩磨轮的优化设计方法,研究了珩磨轮的特殊制造工艺中存在的拨模干涉检验、干涉修正及金属模的加工方法等问题。深入研究了基于Gleason制螺旋锥齿轮铣齿机的珩磨轮的制造方法,详细介绍了产品轮及珩磨轮的齿面几何参数的计算方法以及加工珩磨轮的刀具及机床调整参数的确定方法。为了解决大规格及单件小批量Gleason制螺旋锥齿轮的制造工艺问题,本文建立了基于通用刀具的螺旋锥齿轮及金刚石修整轮制造体系,深入研究了粗、精加工中刀位轨迹的规划及刀具位姿的确定方法,并将研究成果应用于螺旋锥齿轮的五轴联动数控加工中,加工实例表明,本文的理论分析、齿面数学模型和刀位计算方法是正确的,基于通用指状刀具的螺旋锥齿轮的制造方法不仅是可以实现的,而且对于某些特定的应用场合是一种经济、高效和具有快速响应能力的制造方法。
The algorithm for the calculation of coordinates of gear tooth surfaces base on both the generating surface and B-spline interpolation are studied in detail, and the applicability of the methods are discussed as well. To solve the refinement problem of hardened tooth surfaces of Gleason spiral bevel and hypoid gears, honing technology is suggested to be adopted for the purpose in this thesis, meanwhile, the optimal design and synthesis methods of horning wheels are studied and the special problems in the arts for the manufacture of horning wheels such as stripping interference, interference relieving methods and the manufacture method of metal die are also studied. The machining method of the horning wheels based on Gleason spiral bevel gear generators are studied in a deepgoing way, the corresponding algorithms to obtain the geometric parameters of both the workpiece and honing wheels, and the parameters of cutter head and machine setting for the machining of horning wheels are introduced in details. In order to solve the art problems in the manufacture of large scale and single or small batch spiral bevel gears as well as diamond dressing wheels, a manufacture system based on general end mills are established, the problems in tool track layout and the tool pose determination for both roughing and finishing process are studied in a deepgoing way. The research achievement has been put into practice on a 5-axis machining center, and the machining example indicates that the theoretical analysis, mathematical model of tooth surfaces, algorithm to calculate tool position are correct, not only the suggested machining method of spiral bevels based on general end mills is feasible, but also economical, efficient and fast response for certain situation.
The algorithm for the calculation of coordinates of gear tooth surfaces base on both the generating surface and B-spline interpolation are studied in detail, and the applicability of the methods are discussed as well. To solve the refinement problem of hardened tooth surfaces of Gleason spiral bevel and hypoid gears, honing technology is suggested to be adopted for the purpose in this thesis, meanwhile, the optimal design and synthesis methods of horning wheels are studied and the special problems in the arts for the manufacture of horning wheels such as stripping interference, interference relieving methods and the manufacture method of metal die are also studied. The machining method of the horning wheels based on Gleason spiral bevel gear generators are studied in a deepgoing way, the corresponding algorithms to obtain the geometric parameters of both the workpiece and honing wheels, and the parameters of cutter head and machine setting for the machining of horning wheels are introduced in details. In order to solve the art problems in the manufacture of large scale and single or small batch spiral bevel gears as well as diamond dressing wheels, a manufacture system based on general end mills are established, the problems in tool track layout and the tool pose determination for both roughing and finishing process are studied in a deepgoing way. The research achievement has been put into practice on a 5-axis machining center, and the machining example indicates that the theoretical analysis, mathematical model of tooth surfaces, algorithm to calculate tool position are correct, not only the suggested machining method of spiral bevels based on general end mills is feasible, but also economical, efficient and fast response for certain situation.
引文
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