弧齿锥齿轮铣齿机主动精度设计方法研究
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摘要
弧齿锥齿轮是重要的机械传动基础元件。弧齿锥齿轮铣齿机的结构和加工调整复杂,是复杂制造装备的典型代表。弧齿锥齿轮铣齿机的精度直接影响弧齿锥齿轮的加工精度,进一步影响齿轮副的传动性能和噪声。合理的精度设计是决定产品性价比和设计成功的关键。传统的精度设计主要是根据给定的机床末端执行机构精度求解传动链中各零部件的精度,是面向“装备”的精度设计,不能很好地适应弧齿锥齿轮这类复杂空间曲面零件高精密加工的精度要求。为此,本文从弧齿锥齿轮的加工精度要求和加工原理出发,对弧齿锥齿轮铣齿机精度设计问题进行了探索研究,以期为以数控弧齿锥齿轮铣齿机为典型代表的复杂制造装备的精度设计提供可行、有效的解决方案。论文主要研究内容和成果如下:
1.构建了面向弧齿锥齿轮加工精度需求的弧齿锥齿轮铣齿机主动精度设计方法,即从加工对象的精度要求和加工原理出发,进行弧齿锥齿轮铣齿机的精度设计。该方法的基本思想是:通过分析弧齿锥齿轮铣齿机的结构及其加工原理,建立铣齿机运动误差与弧齿锥齿轮齿面加工误差之间的映射关系——齿面加工误差模型;基于齿面加工误差模型,建立齿面加工精度模型;依据齿面加工精度模型,将弧齿锥齿轮的加工精度要求向铣齿机各轴运动精度进行分配。
2.在分析弧齿锥齿轮铣齿机结构和加工原理的基础上,建立了类格里森凤凰I弧齿锥齿轮铣齿机加工模型;并通过虚拟加工,对加工模型进行了验证。
3.为获得用于建立齿面加工误差模型的弧齿锥齿轮齿面离散点坐标,依据空间坐标变换方法和啮合理论,建立了弧齿锥齿轮齿面方程及基于旋转投影变换求解齿面离散点坐标的计算方法;并通过弧齿锥齿轮齿面三维模型和齿面点坐标理论值与计算值的对比分析,验证了弧齿锥齿轮齿面方程及齿面离散点坐标计算方法的正确性。
4.在分析弧齿锥齿轮齿面加工误差影响因素的基础上,依据弧齿锥齿轮齿面模型,分析了坐标轴式数控弧齿锥齿轮铣齿机单轴运动误差度对弧齿锥齿轮齿面离散点处加工误差的影响规律;选取齿距偏差为弧齿锥齿轮齿面加工误差检验项目,建立了弧齿锥齿轮齿面加工误差模型。
5.基于弧齿锥齿轮齿面加工误差模型,建立了弧齿锥齿轮齿面加工精度模型。对弧齿锥齿轮齿面加工精度进行灵敏度分析,获得了齿面加工精度对机床各轴运动精度的灵敏度,结合精度分配和机床精度储备原则,建立了弧齿锥齿轮铣齿机主动精度设计模型。
6.将上述成果应用于天津第一机床总厂开发的YK2275型坐标轴式数控弧齿锥齿轮铣齿机精度设计,确定了弧齿锥齿轮加工精度要求为6级时,YK2275型数控弧齿锥齿轮铣齿机X、Y、Z直线轴定位精度和A、B回转轴定位精度的设计参考值。
本文研究的主动精度设计方法,虽然其具体对象是弧齿锥齿轮铣齿机,但就其理念和原理而言,也适用其它基于复杂加工原理的制造装备精度设计,具有一般性意义。
Spiral bevel gear is an important driving component in mechanical engineering. The structure and manufacturing adjustment of spiral bevel gear milling machine tool are complex, it is the typical representative of complex manufacturing equipment. Spiral bevel gear milling machine tool’s precision directly influences spiral bevel gear’s machining precision, and further influences the transmission performance and noise of the gear pair. Reasonable precision design is the key to influence the product’s cost performance and obtain a successful design. The traditional precision design method is primarily to calculate the precision of every machine tool parts in the transmission chain based on the given precision of machine tool’s terminal actuators, it is the precision design which is oriented to the manufacturing equipments, but it can’t meet the machining precision requirement of the complicated space surface part similar to spiral bevel gear. Therefore, this paper explores the issues on spiral bevel gear milling machine tool’s precision design from spiral bevel gear’s precision requirement and machining mechanism, which aims to offer one feasible and effective solution on the problem of precision design of the NC spiral bevel gear milling machine tool, a typical representative of complex manufacturing equipment. The following contributions and main content have been made by this research:
1. The spiral bevel gear’s machining precision requirement-oriented active precision design method of spiral bevel gear milling machine tool is proposed. It designs spiral bevel gear milling machine tool’s precision from spiral bevel gear’s machining precision requirement and machining mechanism. The basic idea of this method is to establish the mapping relationship between the spiral bevel gear milling machine tool’s motion error and spiral bevel gear’s machining error, the error mapping modle, and then to establish the spiral bevel gear’s machining precision modle based on the error mapping modle. Finally, transform spiral bevel gear’s machining precision requirement to the motion precision of spiral bevel gear milling machine tool’s axis of motion according to the machining precision modle.
2. The machining model of the spiral bevel gear milling machine tool similar to Gleason Phoenix one is established based on analyzing the spiral bevel gear milling machine tool’s structure and machining mechanism, and it is validated by virtual machining.
3. In order to obtain the coordinates of discrete points on spiral bevel gear’s tooth surface used to establish the error mapping modle, the equation of spiral bevel gear’s tooth surface and the coordinate calculation method of the discrete points on spiral bevel gear’s tooth surface based on the rotational projection transformation are established with the method of space coordinate transformation and meshing theory. The equation and calculation method are validated by the three dimensional model of spiral bevel gear’s tooth surface and the comparative analysis between the theoretical value and calculated value of the coordinates of discrete points on spiral bevel gear’s tooth surface.
4. The spiral bevel gear’s tooth surface error model is established, based on analyzing the influencing factors and the influence characteristic of spiral bevel gear milling machine tool’s motion error to spiral bevel gear’s tooth surface machining error, choosing the circular pitch error as spiral bevel gear’s machining error inspection item.
5. The spiral bevel gear’s machining precision modle is established based on the machining error mapping modle. Active precision design model of spiral bevel gear milling machine tool also is established with the accuracy distribution, machine tool precision reserve principle and sensitivity of spiral bevel gear’s machining precision to the machine tool’s kinematic precision by sensitivity analysis on the machining precision.
6. The above result is applied to the precision design of YK2275 NC spiral bevel gear milling machine tool developed by Tianjin No.1 Machine Tool Works. And the design reference value of positioning accurcay of X, Y, Z axis and A, B rotation axis of YK2275 is determined as spiral bevel gear’s machining precision grade is six.
Although the research object of the active precision design method in this paper is spiral bevel gear milling machine tool, but as far as the design concept and principle are concerned, the method is universal and also is applicable to the other manufacturing equipment’s precision design based on the complicated machining mechanism.
1.构建了面向弧齿锥齿轮加工精度需求的弧齿锥齿轮铣齿机主动精度设计方法,即从加工对象的精度要求和加工原理出发,进行弧齿锥齿轮铣齿机的精度设计。该方法的基本思想是:通过分析弧齿锥齿轮铣齿机的结构及其加工原理,建立铣齿机运动误差与弧齿锥齿轮齿面加工误差之间的映射关系——齿面加工误差模型;基于齿面加工误差模型,建立齿面加工精度模型;依据齿面加工精度模型,将弧齿锥齿轮的加工精度要求向铣齿机各轴运动精度进行分配。
2.在分析弧齿锥齿轮铣齿机结构和加工原理的基础上,建立了类格里森凤凰I弧齿锥齿轮铣齿机加工模型;并通过虚拟加工,对加工模型进行了验证。
3.为获得用于建立齿面加工误差模型的弧齿锥齿轮齿面离散点坐标,依据空间坐标变换方法和啮合理论,建立了弧齿锥齿轮齿面方程及基于旋转投影变换求解齿面离散点坐标的计算方法;并通过弧齿锥齿轮齿面三维模型和齿面点坐标理论值与计算值的对比分析,验证了弧齿锥齿轮齿面方程及齿面离散点坐标计算方法的正确性。
4.在分析弧齿锥齿轮齿面加工误差影响因素的基础上,依据弧齿锥齿轮齿面模型,分析了坐标轴式数控弧齿锥齿轮铣齿机单轴运动误差度对弧齿锥齿轮齿面离散点处加工误差的影响规律;选取齿距偏差为弧齿锥齿轮齿面加工误差检验项目,建立了弧齿锥齿轮齿面加工误差模型。
5.基于弧齿锥齿轮齿面加工误差模型,建立了弧齿锥齿轮齿面加工精度模型。对弧齿锥齿轮齿面加工精度进行灵敏度分析,获得了齿面加工精度对机床各轴运动精度的灵敏度,结合精度分配和机床精度储备原则,建立了弧齿锥齿轮铣齿机主动精度设计模型。
6.将上述成果应用于天津第一机床总厂开发的YK2275型坐标轴式数控弧齿锥齿轮铣齿机精度设计,确定了弧齿锥齿轮加工精度要求为6级时,YK2275型数控弧齿锥齿轮铣齿机X、Y、Z直线轴定位精度和A、B回转轴定位精度的设计参考值。
本文研究的主动精度设计方法,虽然其具体对象是弧齿锥齿轮铣齿机,但就其理念和原理而言,也适用其它基于复杂加工原理的制造装备精度设计,具有一般性意义。
Spiral bevel gear is an important driving component in mechanical engineering. The structure and manufacturing adjustment of spiral bevel gear milling machine tool are complex, it is the typical representative of complex manufacturing equipment. Spiral bevel gear milling machine tool’s precision directly influences spiral bevel gear’s machining precision, and further influences the transmission performance and noise of the gear pair. Reasonable precision design is the key to influence the product’s cost performance and obtain a successful design. The traditional precision design method is primarily to calculate the precision of every machine tool parts in the transmission chain based on the given precision of machine tool’s terminal actuators, it is the precision design which is oriented to the manufacturing equipments, but it can’t meet the machining precision requirement of the complicated space surface part similar to spiral bevel gear. Therefore, this paper explores the issues on spiral bevel gear milling machine tool’s precision design from spiral bevel gear’s precision requirement and machining mechanism, which aims to offer one feasible and effective solution on the problem of precision design of the NC spiral bevel gear milling machine tool, a typical representative of complex manufacturing equipment. The following contributions and main content have been made by this research:
1. The spiral bevel gear’s machining precision requirement-oriented active precision design method of spiral bevel gear milling machine tool is proposed. It designs spiral bevel gear milling machine tool’s precision from spiral bevel gear’s machining precision requirement and machining mechanism. The basic idea of this method is to establish the mapping relationship between the spiral bevel gear milling machine tool’s motion error and spiral bevel gear’s machining error, the error mapping modle, and then to establish the spiral bevel gear’s machining precision modle based on the error mapping modle. Finally, transform spiral bevel gear’s machining precision requirement to the motion precision of spiral bevel gear milling machine tool’s axis of motion according to the machining precision modle.
2. The machining model of the spiral bevel gear milling machine tool similar to Gleason Phoenix one is established based on analyzing the spiral bevel gear milling machine tool’s structure and machining mechanism, and it is validated by virtual machining.
3. In order to obtain the coordinates of discrete points on spiral bevel gear’s tooth surface used to establish the error mapping modle, the equation of spiral bevel gear’s tooth surface and the coordinate calculation method of the discrete points on spiral bevel gear’s tooth surface based on the rotational projection transformation are established with the method of space coordinate transformation and meshing theory. The equation and calculation method are validated by the three dimensional model of spiral bevel gear’s tooth surface and the comparative analysis between the theoretical value and calculated value of the coordinates of discrete points on spiral bevel gear’s tooth surface.
4. The spiral bevel gear’s tooth surface error model is established, based on analyzing the influencing factors and the influence characteristic of spiral bevel gear milling machine tool’s motion error to spiral bevel gear’s tooth surface machining error, choosing the circular pitch error as spiral bevel gear’s machining error inspection item.
5. The spiral bevel gear’s machining precision modle is established based on the machining error mapping modle. Active precision design model of spiral bevel gear milling machine tool also is established with the accuracy distribution, machine tool precision reserve principle and sensitivity of spiral bevel gear’s machining precision to the machine tool’s kinematic precision by sensitivity analysis on the machining precision.
6. The above result is applied to the precision design of YK2275 NC spiral bevel gear milling machine tool developed by Tianjin No.1 Machine Tool Works. And the design reference value of positioning accurcay of X, Y, Z axis and A, B rotation axis of YK2275 is determined as spiral bevel gear’s machining precision grade is six.
Although the research object of the active precision design method in this paper is spiral bevel gear milling machine tool, but as far as the design concept and principle are concerned, the method is universal and also is applicable to the other manufacturing equipment’s precision design based on the complicated machining mechanism.
引文
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