摆线齿锥齿轮全数控加工方法及软件实现
|
摘要
伴随着我国汽车制造行业的快速发展,齿轮作为汽车所有零配件里最重要的部件,其设计原理和加工方法的选择也越来越受重视。摆线齿锥齿轮和准双曲面齿轮(以下简称锥齿轮)由于其承载能力高、传动平稳、噪音小、结构紧凑等优点,逐渐在汽车后桥传动上得到了广泛的应用。摆线齿锥齿轮的几何参数设计及加工调整参数计算的精确性直接影响了锥齿轮啮合传动质量、工作寿命及可靠性等。
目前在国际的摆线齿锥齿轮制造生产中,较为广泛使用的是克林贝格公司的CDS摆线锥齿轮设计系统软件。但是由于齿锥齿轮的设计与加工技术一直以来被瑞士前奥利康公司及德国的克林根贝格公司所垄断,流入国内的技术资料十分有限,国内学者对该领域的研究也相对较少,所以对其铣齿加工原理、调整计算、成套加工设备制造方面的技术掌握都十分不足,与国外先进水平相差很大。目前国外广泛采用全数控机床加工摆线齿锥齿轮,该方法加工效率高,加工出的锥齿轮的精度较好。国内还主要采用传统的摆线齿锥齿轮铣齿机加工摆线齿锥齿轮,而对全数控加工摆线齿锥齿轮的研究较少,因此研究摆线齿锥齿轮的几何参数、调整参数计算和全数控加工摆线齿锥齿轮的原理,对加速国产全数控摆线齿锥齿轮铣齿机及其成套设备的开发,提高我国摆线齿锥齿轮的加工水平具有重要的意义。
本文根据齿轮啮合理论及相关手册,对摆线齿锥齿轮几何参数设计和计算切齿调整参数进行理论研究。在此理论研究的基础上,建立奥利康制摆线齿锥齿轮齿面几何参数如径矢、法矢等的统一计算模型,分析了其求解方法,并根据该模型进行齿面接触分析研究。在以上的理论研究基础上,应用Visual C++编程工具,研发出在Windows环境下的摆线齿锥齿轮设计软件系统。通过对摆线齿锥齿轮全数控加工的机床控制原理研究,建立了摆线齿锥齿轮全数控加工的数学模型,并根据该模型研究了摆线齿锥齿轮全数控加工的刀位计算方法。根据摆线齿锥齿轮全数控加工控制原理,在VERICUT数控仿真软件构建了摆线齿锥齿轮全数控加工虚拟切齿平台,并进行切齿仿真实验,验证了该摆线齿锥齿轮全数控加工的数学模型和摆线齿锥齿轮设计软件系统计算的正确性。
As the rapid development of the automobile manufacturing industry, as the most important part of the automobile accessories, the development of gear’s design and machining mode has got more attention than before. The epicycolid bevel gear and hypoid gear (bevel gear for short hereinafter) is widely used in the rear axle of the transmission. Its advantages as great carrying capacity, steady driving system, low noise, and compact conformation make it an important accessory of the vehicle power transmission system.
Bevel gear's geometric parameter design and processing adjustment parameter transmission performance evaluation and so on computation accurate immediate influence bevel gear meshing transmission quality, working life and reliability key parameters. At present, the Klingelnberg corporation’s CDS software is widely applied in the international epicycolid bevel gear and hypoid gear manufacture industry. Because the bevel gear’s designing and machining technique are monopolized by Switzerland ex-Oerlikon corporation and German Klingelnberg corporation. the technical data drifting into China is limited, Chinese scholars in the field study also relatively small, The researches about this area are less in home, therefore the principle of its milling process, adjusting the terms of the manufacture of complete sets of processing equipment to master the technology are less, and foreign advanced levels vary considerably. At present overseas widely uses the entire numerically-controlled machine tool processing cycloidal tooth bevel gear, this method processing efficiency is high, bevel gear's precision which processes is good. The home also mainly uses traditional the cycloidal tooth bevel gear milled tooth machining cycloidal tooth bevel gear, but are few to the entire numerical control processing cycloidal tooth bevel gear's research, Therefore research cycloidal tooth bevel gear's geometric parameter, adjustment parameter computation and entire numerical control processing cycloidal tooth bevel gear's principle, to accelerates the domestically produced entire numerical control cycloidal tooth bevel gear gear cutter and complete set of equipment's development, raising our country cycloidal tooth bevel gear's processing level to have the vital significance.
This article first according to the gear meshing theory and the related handbook, conducts the fundamental research to the cycloidal tooth bevel gear geometric parameter design and the computation cutting tooth adjustment parameter. In this fundamental research foundation, it establishes Oerlikon system cycloidal tooth bevel gear tooth face geometric parameter like diameter arrow, french arrow and so on unification computation model, has analyzed its solution method, and conducts the tooth face contact analytical study according to this model. In the above fundamental research foundation, using Visual the C++ programming tool, researches and develops under the Windows environment cycloidal tooth bevel gear designing software system. Through to the cycloidal tooth bevel gear entire numerical control processing's control principle research, has established the cycloidal tooth bevel gear entire numerical control processing mathematical model, and acted according to this model analysis cycloidal tooth bevel gear entire numerical control processing the knife position computational method. According to cycloidal tooth bevel gear entire numerical control processing control principle, through construction cycloidal tooth bevel gear entire numerical control processing hypothesized cutting tooth platform in VERICUT numerical control simulation software, and carries on the cutting tooth simulation experiment, has confirmed this cycloidal tooth bevel gear entire numerical control processing mathematical model and cycloidal tooth bevel gear design software system computation accuracy.
目前在国际的摆线齿锥齿轮制造生产中,较为广泛使用的是克林贝格公司的CDS摆线锥齿轮设计系统软件。但是由于齿锥齿轮的设计与加工技术一直以来被瑞士前奥利康公司及德国的克林根贝格公司所垄断,流入国内的技术资料十分有限,国内学者对该领域的研究也相对较少,所以对其铣齿加工原理、调整计算、成套加工设备制造方面的技术掌握都十分不足,与国外先进水平相差很大。目前国外广泛采用全数控机床加工摆线齿锥齿轮,该方法加工效率高,加工出的锥齿轮的精度较好。国内还主要采用传统的摆线齿锥齿轮铣齿机加工摆线齿锥齿轮,而对全数控加工摆线齿锥齿轮的研究较少,因此研究摆线齿锥齿轮的几何参数、调整参数计算和全数控加工摆线齿锥齿轮的原理,对加速国产全数控摆线齿锥齿轮铣齿机及其成套设备的开发,提高我国摆线齿锥齿轮的加工水平具有重要的意义。
本文根据齿轮啮合理论及相关手册,对摆线齿锥齿轮几何参数设计和计算切齿调整参数进行理论研究。在此理论研究的基础上,建立奥利康制摆线齿锥齿轮齿面几何参数如径矢、法矢等的统一计算模型,分析了其求解方法,并根据该模型进行齿面接触分析研究。在以上的理论研究基础上,应用Visual C++编程工具,研发出在Windows环境下的摆线齿锥齿轮设计软件系统。通过对摆线齿锥齿轮全数控加工的机床控制原理研究,建立了摆线齿锥齿轮全数控加工的数学模型,并根据该模型研究了摆线齿锥齿轮全数控加工的刀位计算方法。根据摆线齿锥齿轮全数控加工控制原理,在VERICUT数控仿真软件构建了摆线齿锥齿轮全数控加工虚拟切齿平台,并进行切齿仿真实验,验证了该摆线齿锥齿轮全数控加工的数学模型和摆线齿锥齿轮设计软件系统计算的正确性。
As the rapid development of the automobile manufacturing industry, as the most important part of the automobile accessories, the development of gear’s design and machining mode has got more attention than before. The epicycolid bevel gear and hypoid gear (bevel gear for short hereinafter) is widely used in the rear axle of the transmission. Its advantages as great carrying capacity, steady driving system, low noise, and compact conformation make it an important accessory of the vehicle power transmission system.
Bevel gear's geometric parameter design and processing adjustment parameter transmission performance evaluation and so on computation accurate immediate influence bevel gear meshing transmission quality, working life and reliability key parameters. At present, the Klingelnberg corporation’s CDS software is widely applied in the international epicycolid bevel gear and hypoid gear manufacture industry. Because the bevel gear’s designing and machining technique are monopolized by Switzerland ex-Oerlikon corporation and German Klingelnberg corporation. the technical data drifting into China is limited, Chinese scholars in the field study also relatively small, The researches about this area are less in home, therefore the principle of its milling process, adjusting the terms of the manufacture of complete sets of processing equipment to master the technology are less, and foreign advanced levels vary considerably. At present overseas widely uses the entire numerically-controlled machine tool processing cycloidal tooth bevel gear, this method processing efficiency is high, bevel gear's precision which processes is good. The home also mainly uses traditional the cycloidal tooth bevel gear milled tooth machining cycloidal tooth bevel gear, but are few to the entire numerical control processing cycloidal tooth bevel gear's research, Therefore research cycloidal tooth bevel gear's geometric parameter, adjustment parameter computation and entire numerical control processing cycloidal tooth bevel gear's principle, to accelerates the domestically produced entire numerical control cycloidal tooth bevel gear gear cutter and complete set of equipment's development, raising our country cycloidal tooth bevel gear's processing level to have the vital significance.
This article first according to the gear meshing theory and the related handbook, conducts the fundamental research to the cycloidal tooth bevel gear geometric parameter design and the computation cutting tooth adjustment parameter. In this fundamental research foundation, it establishes Oerlikon system cycloidal tooth bevel gear tooth face geometric parameter like diameter arrow, french arrow and so on unification computation model, has analyzed its solution method, and conducts the tooth face contact analytical study according to this model. In the above fundamental research foundation, using Visual the C++ programming tool, researches and develops under the Windows environment cycloidal tooth bevel gear designing software system. Through to the cycloidal tooth bevel gear entire numerical control processing's control principle research, has established the cycloidal tooth bevel gear entire numerical control processing mathematical model, and acted according to this model analysis cycloidal tooth bevel gear entire numerical control processing the knife position computational method. According to cycloidal tooth bevel gear entire numerical control processing control principle, through construction cycloidal tooth bevel gear entire numerical control processing hypothesized cutting tooth platform in VERICUT numerical control simulation software, and carries on the cutting tooth simulation experiment, has confirmed this cycloidal tooth bevel gear entire numerical control processing mathematical model and cycloidal tooth bevel gear design software system computation accuracy.
引文
[1]董学朱.延伸外摆线准双曲面齿轮几何参数计算法的改进.机械传动,1998,22(2):9-13
[2]董学朱.摆线齿锥齿轮及准双曲面齿轮设计和制造.北京,机械工业出版社,2003.2-5
[3]刘鹄然,陈良玉,刘志峰.奥利康与克林根贝尔格制铣齿机工作原理的新认识.机械传动,1998,22(3):36-37
[4]董学朱.延伸外摆线锥齿轮切齿调整计算法的改进.机械传动,1997,21(4):41-47
[5]吴大任.骆家舜.齿轮啮合理论.北京:科学出版社,1985
[6]梅向明.黄敬之.微分几何.北京:高等教育出版社,2003
[7]吴序堂.齿轮啮合理论.北京:机械工业出版社,1982
[8]郑昌启.弧齿锥齿轮和准双曲面齿轮.北京:机械工业出版社,1988
[9]曾韬.螺旋锥齿轮设计与加工.哈尔滨,哈尔滨工业大学出版社,1989
[10]董学朱.齿轮啮合理论基础.北京:机械工业出版社,1989
[11]董学朱.摆线齿锥齿轮连续分齿法铣齿原理的研究,机械传动,1999,23(2):29-30
[12]《齿轮制造手册》编辑委员会.齿轮制造手册.北京:机械工业出版设,1997,12
[13]董学朱.摆线齿锥齿轮及准双曲面齿轮设计与制造.北京:机械工业出版社,2002
[14]张艳红.用Free-form型机床加工螺旋锥齿轮的研究和软件系统开发:[博士学位论文].西安:西安交通大学,1999
[15]吴联银,魏洪欣,王小椿.延伸外摆线锥齿轮的成形原理及齿面结构研究.西安交通大学学报,2001,35(1):43-46
[16]李海涛,魏文军.摆线齿锥齿轮齿面接触区的计算机辅助分析,中国农业大学学报,2004,9(5):45-50
[17] Herman J.Stadtfeld.Oerlikon Bevel and Hypoid Gears Calculation,Manufacturing and Optimization Collected Publication.Machine Tool Works Oerlinkon-Buhrle Ltd.1990/1991
[18] Herman J.Stadtfeld.Handbook of Bevel and Hypoid Gears.Rochester Institute of Technology,1993
[19] Herman J.Stadtfeld.Gleason Bevel Gear Technology.The Gleason works,1994/1995
[20] M.Vimercati.Mathematical model for tooth surfaces representation of face-hobbed hypoid gears and its application to contract analysis and stress calculation.Mechanism and Machine Theory,42(2007):668-690
[21] Herman J.Stadtfeld.Free-form CNC Bevel Gear Cutting Machine Comparison to the Cradle Style Machine.Gleason works,1993
[22]刘志峰,陈良玉,孙志礼等.Klingelnberg摆线锥齿轮轮齿接触分析与预报仿真,东北大学学报,1999,22(6):594-587
[23] Yi-Pei Shih,Zhang-Hua Feng,Grandle C.Y.Lin.Mathematical Model for a Universal Face Hobbing Hypoid Gear Generator.Journal of Mechanical Design,January 2007,Vol.129:28-47
[24]北京齿轮厂.螺旋锥齿轮.北京:科学出版社,1974
[25]刘惟信.汽车设计丛书:圆锥齿轮与准双曲线齿轮传动.北京:人民交通出版社,1980
[26]四川省机械工业局编著.齿轮刀具设计理论基础(下册).北京:机械工业出版设,1983
[27]李特文[苏联].齿轮啮合原理(第二版).上海:上海科学技术出版设,1984
[28]李巍,李剑锋,王青云等.克林贝格摆线齿锥齿轮产形轮齿面方程,机械设计,2006,44(3):46-48
[29] Robert N.Goldrich.Theory of 6-Axis CNC Generation of Spiral Bevel and Hypoid Gears.AGMAF all Technical Meeting,Pitsburgh,1989
[30]刘志峰.摆线齿锥齿轮传动原理及啮合性能模糊优化的研究:[博士学位论文].沈阳:东北大学,2001,2.39-40
[31]陈芳,周云飞,李小清.奥利康制齿轮数控加工运动变换分析.机械与电子,2002(1):73-75
[32] Yi-Pei Shih,Zhang-Hua Feng.Flank Modification Methodology for Face-Hoobing Hypoid Gears Based on Ease-Off Topography.Journal of Mechanical Design,December 2007,Vol.129:1294-1302
[33] Yi-Pei Shih,Zhang-Hua Feng.Flank Correction for Spiral Bevel and Hypoid Gears on a Six-Axis CNC Hypoid Genenator.Journal of Mechanical Design,June 2008,Vol.130:062604-1—062604-11
[34] Qi Fan.Enhanced Algorithms of Contract Simulation for Hypoid Gear Drives Produced by Face-Milling and Face-Hobbing Processes.Journal of Mechanical Design,January 2007,Vol.129:31-37
[35] Wei-Shiang Wang,Zhang-Hua Fong.A dual face-hobbing method for the cycloidal crowning of spur gears.Mechanism and Machine Theory,43(2008):1416-1430
[36] F.L.Litvin.Gear Geometry and Applied Theory.Prentice Hall,Englewood Cliffs,NJ,1994
[37] Litvin F.L.,Chaing W.S.,Lundy M.etal.Design of Pitch Cones of Face Hobbed Hypoid Gears.ASME Journal of Mechanical Design,1990,Vol.122:413-418
[38]徐潮德.延伸外摆线锥齿轮齿面接触区的位移特性.汽齿科技,2001,1:39-50
[39]徐士良.常用数值算法程序集(C语言描述).北京:清华大学出版社,2004
[40]李云龙,曹岩.数控机床加工仿真系统VERICUT.西安:西安交通大学出版社,2005
[41]王亚平.基于VERICUT的数控加工仿真及优化的应用.组合机床与自动化加工技术,2004,3:31-33
[42]张冲.基于VERICUT的虚拟制造技术应用.合肥工业大学学报(自然科学版),2004,27(1):109-112
[43] CGTech.VERICUT User Manual.2001
[2]董学朱.摆线齿锥齿轮及准双曲面齿轮设计和制造.北京,机械工业出版社,2003.2-5
[3]刘鹄然,陈良玉,刘志峰.奥利康与克林根贝尔格制铣齿机工作原理的新认识.机械传动,1998,22(3):36-37
[4]董学朱.延伸外摆线锥齿轮切齿调整计算法的改进.机械传动,1997,21(4):41-47
[5]吴大任.骆家舜.齿轮啮合理论.北京:科学出版社,1985
[6]梅向明.黄敬之.微分几何.北京:高等教育出版社,2003
[7]吴序堂.齿轮啮合理论.北京:机械工业出版社,1982
[8]郑昌启.弧齿锥齿轮和准双曲面齿轮.北京:机械工业出版社,1988
[9]曾韬.螺旋锥齿轮设计与加工.哈尔滨,哈尔滨工业大学出版社,1989
[10]董学朱.齿轮啮合理论基础.北京:机械工业出版社,1989
[11]董学朱.摆线齿锥齿轮连续分齿法铣齿原理的研究,机械传动,1999,23(2):29-30
[12]《齿轮制造手册》编辑委员会.齿轮制造手册.北京:机械工业出版设,1997,12
[13]董学朱.摆线齿锥齿轮及准双曲面齿轮设计与制造.北京:机械工业出版社,2002
[14]张艳红.用Free-form型机床加工螺旋锥齿轮的研究和软件系统开发:[博士学位论文].西安:西安交通大学,1999
[15]吴联银,魏洪欣,王小椿.延伸外摆线锥齿轮的成形原理及齿面结构研究.西安交通大学学报,2001,35(1):43-46
[16]李海涛,魏文军.摆线齿锥齿轮齿面接触区的计算机辅助分析,中国农业大学学报,2004,9(5):45-50
[17] Herman J.Stadtfeld.Oerlikon Bevel and Hypoid Gears Calculation,Manufacturing and Optimization Collected Publication.Machine Tool Works Oerlinkon-Buhrle Ltd.1990/1991
[18] Herman J.Stadtfeld.Handbook of Bevel and Hypoid Gears.Rochester Institute of Technology,1993
[19] Herman J.Stadtfeld.Gleason Bevel Gear Technology.The Gleason works,1994/1995
[20] M.Vimercati.Mathematical model for tooth surfaces representation of face-hobbed hypoid gears and its application to contract analysis and stress calculation.Mechanism and Machine Theory,42(2007):668-690
[21] Herman J.Stadtfeld.Free-form CNC Bevel Gear Cutting Machine Comparison to the Cradle Style Machine.Gleason works,1993
[22]刘志峰,陈良玉,孙志礼等.Klingelnberg摆线锥齿轮轮齿接触分析与预报仿真,东北大学学报,1999,22(6):594-587
[23] Yi-Pei Shih,Zhang-Hua Feng,Grandle C.Y.Lin.Mathematical Model for a Universal Face Hobbing Hypoid Gear Generator.Journal of Mechanical Design,January 2007,Vol.129:28-47
[24]北京齿轮厂.螺旋锥齿轮.北京:科学出版社,1974
[25]刘惟信.汽车设计丛书:圆锥齿轮与准双曲线齿轮传动.北京:人民交通出版社,1980
[26]四川省机械工业局编著.齿轮刀具设计理论基础(下册).北京:机械工业出版设,1983
[27]李特文[苏联].齿轮啮合原理(第二版).上海:上海科学技术出版设,1984
[28]李巍,李剑锋,王青云等.克林贝格摆线齿锥齿轮产形轮齿面方程,机械设计,2006,44(3):46-48
[29] Robert N.Goldrich.Theory of 6-Axis CNC Generation of Spiral Bevel and Hypoid Gears.AGMAF all Technical Meeting,Pitsburgh,1989
[30]刘志峰.摆线齿锥齿轮传动原理及啮合性能模糊优化的研究:[博士学位论文].沈阳:东北大学,2001,2.39-40
[31]陈芳,周云飞,李小清.奥利康制齿轮数控加工运动变换分析.机械与电子,2002(1):73-75
[32] Yi-Pei Shih,Zhang-Hua Feng.Flank Modification Methodology for Face-Hoobing Hypoid Gears Based on Ease-Off Topography.Journal of Mechanical Design,December 2007,Vol.129:1294-1302
[33] Yi-Pei Shih,Zhang-Hua Feng.Flank Correction for Spiral Bevel and Hypoid Gears on a Six-Axis CNC Hypoid Genenator.Journal of Mechanical Design,June 2008,Vol.130:062604-1—062604-11
[34] Qi Fan.Enhanced Algorithms of Contract Simulation for Hypoid Gear Drives Produced by Face-Milling and Face-Hobbing Processes.Journal of Mechanical Design,January 2007,Vol.129:31-37
[35] Wei-Shiang Wang,Zhang-Hua Fong.A dual face-hobbing method for the cycloidal crowning of spur gears.Mechanism and Machine Theory,43(2008):1416-1430
[36] F.L.Litvin.Gear Geometry and Applied Theory.Prentice Hall,Englewood Cliffs,NJ,1994
[37] Litvin F.L.,Chaing W.S.,Lundy M.etal.Design of Pitch Cones of Face Hobbed Hypoid Gears.ASME Journal of Mechanical Design,1990,Vol.122:413-418
[38]徐潮德.延伸外摆线锥齿轮齿面接触区的位移特性.汽齿科技,2001,1:39-50
[39]徐士良.常用数值算法程序集(C语言描述).北京:清华大学出版社,2004
[40]李云龙,曹岩.数控机床加工仿真系统VERICUT.西安:西安交通大学出版社,2005
[41]王亚平.基于VERICUT的数控加工仿真及优化的应用.组合机床与自动化加工技术,2004,3:31-33
[42]张冲.基于VERICUT的虚拟制造技术应用.合肥工业大学学报(自然科学版),2004,27(1):109-112
[43] CGTech.VERICUT User Manual.2001