指形铣刀的参数化设计及其数控加工
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摘要
在日常的机械装备中,齿轮作为最常用、最重要的零件被广泛的应用。它在机械传动中主要起传递扭矩,还有分度、定位等作用。在齿轮的加工过程中,主要采用的成形方法有滚齿、插齿和铣齿,对于大模数(通常指模数大于或等于10)齿轮的加工主要采用的铣齿加工。因此指形齿轮铣刀在大模数齿轮加工中有着极为广泛的应用,尤其在人字齿等特殊的大型齿轮加工中,更有着不可代替的用途。
等螺旋角指形齿轮铣刀由于具有切削平稳、生产效率高、刀具制造成本低等优点,从而得到了日益广泛的应用。但是等螺旋角指形齿轮铣刀的设计、刃磨都不具有通用性,不同的齿轮参数对应着不同的形状和角度,因此,等螺旋角指形齿轮铣刀的设计和刃磨是制造和重磨中的关键一环。然而目前还只能依靠查表计算的方式来计算刀具参数,依靠样板,手工刃磨来制造这种刀具,还没有设计此类刀具的参数化方法和刃磨这种刀具的数控刃磨机。
本文通过建立等螺旋角指形齿轮铣刀的外形,切削刃等的数学模型,并对影响齿轮强度和精度的关键参数进行优化,提出了指形铣刀的参数化设计方法,并开发了等螺旋角指形齿轮铣刀参数化设计软件;对磨削指形铣刀的刀具轨迹进行了规划,使之能根据刀具参数的不同实时生成不同的加工程序;设计开发了基于开放式控制系统的等螺旋角指形齿轮铣刀五轴四联动数控磨床;最后,对指形铣刀在该机床上进行了切削验证。
本文完成了指形铣刀的参数化设计系统的开发,设计改造成功一台五轴四联动的数控刃磨设备。可以实现完整的指形铣刀的参数化设计、刃磨加工,不但满足了企业的日常需求,而且为以后开发其它类似的刀具参数化设计系统、数控刀具刃磨设备提供参考。
In the daily mechanical equipments, gears are widely used as the most common and most important parts. They mainly act the role of transmitting torque power, indexing and locating in the mechanical transmission. In the gear processing, the main forming methods include gear hobbing, gear shaping and gear milling. For the processing of large module gear (whose module is usually larger than or equal to 10 ), the gear milling is the mainly processing method. Therefore, the finger-type milling cutters are widely used in the processing of the large module gears, especially in the processing of special large gear such as gears with herringbone teeth and so on, the finger-type milling cutters plays an important part.
The finger-type milling cutters with equal helix angles, which own more advantages such as cutting smoothly, higher production capability and lower tool manufacturing cost, are increasingly widely used. But, the design and the grinding of the finger-type milling cutters with equal helix angles is ununiversal, and the different gear parameters are corresponding to different shapes and angles, As a result, the design and grinding of the finger-type milling cutters with equal helix angles is crucial in the machining and regrinding. However, at present, there is no parametric method for the design of the cutter and no CNC tool grinding machine for grinding the cutter, and usually, the only way is looking-up tables for calculating the tool parameters and manual grinding for grinding the tools.
According to the modeling for the figure and cutting edge of finger-type milling cutters with equal helix angles, and the optimizing for the critical parameters of the gear intensity and accuracy, the parametric design method of the finger-type milling cutter has been proposed, and the parametric design software of finger-type milling cutters with equal helix angles has been developed; The cutter trace of the grinding finger-type milling cutter has been planed, which can generate the processing codes just in time according to the different tool parameters, so that the tool grinding can be processing smoothly; The four-linked with five-axis CNC grinding machine of the finger-type milling cutters with equal helix angles has been designed based on open CNC controller by adopting the googol motion control card; Finally, the success cutting test has been implemented by this machine tool for grinding of the finger-type milling cutter.
The development of the parametric design system for finger-type milling cutter and the successfully reforming of the four-linked with five-axis CNC grinding equipment is the study result. Which realizes that the parametric design of the finger-type cutter and the grinding process, and not only meets the daily needs of the enterprise, but also provides references for developing the other similar tool parametric design system and designing the CNC tool grinding equipment in the future.
等螺旋角指形齿轮铣刀由于具有切削平稳、生产效率高、刀具制造成本低等优点,从而得到了日益广泛的应用。但是等螺旋角指形齿轮铣刀的设计、刃磨都不具有通用性,不同的齿轮参数对应着不同的形状和角度,因此,等螺旋角指形齿轮铣刀的设计和刃磨是制造和重磨中的关键一环。然而目前还只能依靠查表计算的方式来计算刀具参数,依靠样板,手工刃磨来制造这种刀具,还没有设计此类刀具的参数化方法和刃磨这种刀具的数控刃磨机。
本文通过建立等螺旋角指形齿轮铣刀的外形,切削刃等的数学模型,并对影响齿轮强度和精度的关键参数进行优化,提出了指形铣刀的参数化设计方法,并开发了等螺旋角指形齿轮铣刀参数化设计软件;对磨削指形铣刀的刀具轨迹进行了规划,使之能根据刀具参数的不同实时生成不同的加工程序;设计开发了基于开放式控制系统的等螺旋角指形齿轮铣刀五轴四联动数控磨床;最后,对指形铣刀在该机床上进行了切削验证。
本文完成了指形铣刀的参数化设计系统的开发,设计改造成功一台五轴四联动的数控刃磨设备。可以实现完整的指形铣刀的参数化设计、刃磨加工,不但满足了企业的日常需求,而且为以后开发其它类似的刀具参数化设计系统、数控刀具刃磨设备提供参考。
In the daily mechanical equipments, gears are widely used as the most common and most important parts. They mainly act the role of transmitting torque power, indexing and locating in the mechanical transmission. In the gear processing, the main forming methods include gear hobbing, gear shaping and gear milling. For the processing of large module gear (whose module is usually larger than or equal to 10 ), the gear milling is the mainly processing method. Therefore, the finger-type milling cutters are widely used in the processing of the large module gears, especially in the processing of special large gear such as gears with herringbone teeth and so on, the finger-type milling cutters plays an important part.
The finger-type milling cutters with equal helix angles, which own more advantages such as cutting smoothly, higher production capability and lower tool manufacturing cost, are increasingly widely used. But, the design and the grinding of the finger-type milling cutters with equal helix angles is ununiversal, and the different gear parameters are corresponding to different shapes and angles, As a result, the design and grinding of the finger-type milling cutters with equal helix angles is crucial in the machining and regrinding. However, at present, there is no parametric method for the design of the cutter and no CNC tool grinding machine for grinding the cutter, and usually, the only way is looking-up tables for calculating the tool parameters and manual grinding for grinding the tools.
According to the modeling for the figure and cutting edge of finger-type milling cutters with equal helix angles, and the optimizing for the critical parameters of the gear intensity and accuracy, the parametric design method of the finger-type milling cutter has been proposed, and the parametric design software of finger-type milling cutters with equal helix angles has been developed; The cutter trace of the grinding finger-type milling cutter has been planed, which can generate the processing codes just in time according to the different tool parameters, so that the tool grinding can be processing smoothly; The four-linked with five-axis CNC grinding machine of the finger-type milling cutters with equal helix angles has been designed based on open CNC controller by adopting the googol motion control card; Finally, the success cutting test has been implemented by this machine tool for grinding of the finger-type milling cutter.
The development of the parametric design system for finger-type milling cutter and the successfully reforming of the four-linked with five-axis CNC grinding equipment is the study result. Which realizes that the parametric design of the finger-type cutter and the grinding process, and not only meets the daily needs of the enterprise, but also provides references for developing the other similar tool parametric design system and designing the CNC tool grinding equipment in the future.
引文
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