直齿锥齿轮精锻模具电极CAD/CAM技术研究与开发
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摘要
随着汽车行业日益发展,汽车差速器、发动机所用的直齿锥齿轮要求强度高和成本低。普通制造工艺是采用切削法加工直齿锥齿轮,但是该加工工艺需要价格昂贵的专业加工设备,并且生产率较低,成本较高。在这样的背景下,直齿锥齿轮的精密锻造工艺引起人们越来越高的关注。
直齿锥齿轮精锻模具通常采用电火花加工制造,需要设计和制造与直齿锥齿轮相同形状的加工电极。直齿锥齿轮模具电极的加工通常在刨齿机上完成,其工艺参数调整困难,劳动强度大,生产准备周期较长。为此,本文结合某齿轮制造企业的实际需求,从分析直齿锥齿轮数学模型入手,研究了渐开线直齿锥齿轮和圆拉直齿锥齿轮的参数化建模方法,并在此基础上研究了齿廓曲面数控加工编程技术。利用Visual C++开发工具,以UG软件为二次开发平台,开发了直齿锥齿轮模具电极CAD/CAM软件。输入相应参数,可自动生成符合标准的渐开线直齿锥齿轮模具电极和圆拉直齿锥齿轮模具电极,给定加工参数,可生成相应的数控铣削刀具轨迹。最后给出了算例,证明了上述工作的可行性及其合理性。
With the development of the automobile industry, a straight bevel gear with high strength and low cost was used in the automobile differential mechanism and the automobile engines. The straight bevel gears are typically shaped which have a high cost and low efficiency, so the technology of precision forging on mold electrode aroused the people higher and higher interest.
Usually straight bevel gear precision forging’s manufactrue is used electrical discharge machining which need a mold electrode the same like a straight bevel gear. Straight bevel gear mold electrode is usually shaped by the gear generator which needs tremendous work to adjust its parameters, the gears shaped by the gear generator have a high labor intecsity and low efficiency and long period of manufacture. The thesis,is designed for requirement of straight bevel gears industry. Beginning with the analysis of the gear engaging theory, this thesis sets up the mathematic model of the profile of the involute gear and achieves the 3D modeling of the complex gear using CAD technology. The thesis also makes a research on the computer aided manufacturing of the gear. Using the Visual C ++ developing tool, the thesis implements the CAD/CAM system for involute gear based second development in UG. Then inputs the parameter of the mold may creat the gear mold electrode autolly and inputs the parameter of the processing may creat milling tool path autolly. Finally the thesis gives the example which has proven the above work is feasibilty an rationality.
直齿锥齿轮精锻模具通常采用电火花加工制造,需要设计和制造与直齿锥齿轮相同形状的加工电极。直齿锥齿轮模具电极的加工通常在刨齿机上完成,其工艺参数调整困难,劳动强度大,生产准备周期较长。为此,本文结合某齿轮制造企业的实际需求,从分析直齿锥齿轮数学模型入手,研究了渐开线直齿锥齿轮和圆拉直齿锥齿轮的参数化建模方法,并在此基础上研究了齿廓曲面数控加工编程技术。利用Visual C++开发工具,以UG软件为二次开发平台,开发了直齿锥齿轮模具电极CAD/CAM软件。输入相应参数,可自动生成符合标准的渐开线直齿锥齿轮模具电极和圆拉直齿锥齿轮模具电极,给定加工参数,可生成相应的数控铣削刀具轨迹。最后给出了算例,证明了上述工作的可行性及其合理性。
With the development of the automobile industry, a straight bevel gear with high strength and low cost was used in the automobile differential mechanism and the automobile engines. The straight bevel gears are typically shaped which have a high cost and low efficiency, so the technology of precision forging on mold electrode aroused the people higher and higher interest.
Usually straight bevel gear precision forging’s manufactrue is used electrical discharge machining which need a mold electrode the same like a straight bevel gear. Straight bevel gear mold electrode is usually shaped by the gear generator which needs tremendous work to adjust its parameters, the gears shaped by the gear generator have a high labor intecsity and low efficiency and long period of manufacture. The thesis,is designed for requirement of straight bevel gears industry. Beginning with the analysis of the gear engaging theory, this thesis sets up the mathematic model of the profile of the involute gear and achieves the 3D modeling of the complex gear using CAD technology. The thesis also makes a research on the computer aided manufacturing of the gear. Using the Visual C ++ developing tool, the thesis implements the CAD/CAM system for involute gear based second development in UG. Then inputs the parameter of the mold may creat the gear mold electrode autolly and inputs the parameter of the processing may creat milling tool path autolly. Finally the thesis gives the example which has proven the above work is feasibilty an rationality.
引文
[1]刘鹄然,赵东福,宋德玉.现代啮合理论.杭州:浙江大学出版社,2008.
[2]王晓东.直齿圆锥锥齿轮模具电极数控铣削编程技术研究.南京:南京航空航天大学硕士论文,2004.
[3]金俊松,夏巨谌.冷精锻修形圆锥齿轮的齿形设计.中国机械工程,2006,10:21~25.
[4]田福祥.直齿锥齿轮精锻模具和电极齿形设计.锻压技术,1998,3:52~55.
[5]戴广军.直齿锥齿轮精锻模具设计.华北水利水电学院学报,2007,6:33~36.
[6] Litvin F L, Gutman Y. A method of local synthesis of gears grounded on connections between the principal and geodetic curvatures of surface. ASME Journal of Mechanical Design, 1981, 103(1):114~125.
[7] Litvin F L, Tsung W J, Lee H T. Generation of spiral bevel gears with conjugated tooth surfaces and tooth contact analysis. NASA Contract analysis, NASA Contract Report 4008. 1987.
[8] Litvin F L, Tsung W J, Coy J J, Heine C. Method for generation of spiral bevel gear with conjugated gear tooth surfaces. ASME Journal of Mechanisms, Transmission and automation in Design, 1987, 109(1):1163~1170.
[9] Baxter M L. Basic geometry and tooth contact of hypoid gears. Industrial Mathemati(2),1962.
[10] Baxter M L.准双曲面齿轮的基本几何及齿轮接触.格里森齿轮技术资料译文集第一分册.北京:机械工业出版社,1986.
[11]朱凤芹.基于Pro/E的标准渐开线直齿圆柱齿轮实体模型的参数化设计.机械设计与制造,2005,08:15~17.
[12]刘洪丽.基于UG二次开发的弧齿锥齿轮参数化造型.锦州:辽宁工学院硕士论文,2007.
[13]李云辉,张军.直齿锥齿轮参数化三维造型及加工应用.制造业信息化,2007,02:25~26.
[14]陈霞,夏巨谌,胡国安.基于UG的直齿锥齿轮的精确建模.中国机械工程,2006,17:107~110.
[15]郑威,夏巨谌等.基于UG的汽车差速器圆锥齿轮参数化造型系统的开发.机械传动,2007,04:28~30.
[16]朱可柯.直齿圆锥锥齿轮数学建模与造型技术的研究.南京:南京航空航天大学硕士论文,2004.
[17]黄翔,李迎光. UG应用开发教程与实例精解.北京:清华大学出版社,2005.
[18]侯永涛,丁向阳. UG/Open二次开发与实例精解.北京:化学工业出版社,2007.
[19]国营渭阳柴油机厂.直齿锥齿轮.北京:国防工业出版社,1978.
[20]谢海波.齿轮参数化CAD系统开发与设计.机械研究与应用,2000,7:56~59.
[21]刘惟信等.圆锥齿轮与双曲面齿轮.北京:人民交通出版社,1980.
[22]周纪良.圆拉直齿锥齿轮设计.拖拉机与农用运输车,2000,6:15~18.
[23] Hong-sen Yan, Tai-shi Lai. Geometry design of an elementary planetary gear train with cylindrical tooth-profiles, Mechanizm and Machine Theory, 2002, Volume 37.
[24] Darle W Dudley, Gear Handbook. McGRAW-Hill Book Company INC. NewYork,1962.
[25]第一汽车制造厂,南开大学齿轮啮合理论研究组.圆拉法加工直齿锥齿轮所依据的两个公式的推导(一).汽车技术,1978,4:75~79.
[26]侯昌友.直齿锥齿轮圆拉法齿轮设计中有关问题的分析和研究.汽车科技,1978,4:49~57.
[27]宋智民,李秀春.直齿锥齿轮的鼓形齿及加工方法初探.机械管理开发,2005,10:18~20.
[28]李凌丰.参数化设计中的尺寸约束传递模型研究.中国机械工程,1996,8:95~98.
[29] DeRose T, Goldman R, Hagen H,etal. Functional composition algorithms via blossoming. ACM Transactions on Graphics, 1993, 12(2):113~115.
[30]朱心雄等.自由曲线曲面造型技术.北京:科学技术出版社,2000.
[31] Seidel H P. Computing B-spline control points using polar forms. Computer Aided Design,1991,23(9):634~640.
[32] Ramshaw L. Blossoms are polar form. Computer Aided Geometric Design, 1989,6(4):323~358.
[33]张幼军,王世杰等编著. UG CAD/CAM基础教程.北京:清华大学出版社,2006.
[34]谢国明等编译. UG CAM实用教程.北京:清华大学出版社,2003.
[35] S.H.Suh. Sculptured surface machining of spiral bevel gears with CNC milling. International Journal of Machine Tools & Manufacture,2001. 41:833~850.
[36] Sarma, R., and Dutta, D., The Geometry and Generation of NC Tool Paths. Journal of Mechanical Design.1997.
[37]董正卫,田立中,付宜利. UG/OPEN API编程基础.北京:清华大学出版社,2002
[2]王晓东.直齿圆锥锥齿轮模具电极数控铣削编程技术研究.南京:南京航空航天大学硕士论文,2004.
[3]金俊松,夏巨谌.冷精锻修形圆锥齿轮的齿形设计.中国机械工程,2006,10:21~25.
[4]田福祥.直齿锥齿轮精锻模具和电极齿形设计.锻压技术,1998,3:52~55.
[5]戴广军.直齿锥齿轮精锻模具设计.华北水利水电学院学报,2007,6:33~36.
[6] Litvin F L, Gutman Y. A method of local synthesis of gears grounded on connections between the principal and geodetic curvatures of surface. ASME Journal of Mechanical Design, 1981, 103(1):114~125.
[7] Litvin F L, Tsung W J, Lee H T. Generation of spiral bevel gears with conjugated tooth surfaces and tooth contact analysis. NASA Contract analysis, NASA Contract Report 4008. 1987.
[8] Litvin F L, Tsung W J, Coy J J, Heine C. Method for generation of spiral bevel gear with conjugated gear tooth surfaces. ASME Journal of Mechanisms, Transmission and automation in Design, 1987, 109(1):1163~1170.
[9] Baxter M L. Basic geometry and tooth contact of hypoid gears. Industrial Mathemati(2),1962.
[10] Baxter M L.准双曲面齿轮的基本几何及齿轮接触.格里森齿轮技术资料译文集第一分册.北京:机械工业出版社,1986.
[11]朱凤芹.基于Pro/E的标准渐开线直齿圆柱齿轮实体模型的参数化设计.机械设计与制造,2005,08:15~17.
[12]刘洪丽.基于UG二次开发的弧齿锥齿轮参数化造型.锦州:辽宁工学院硕士论文,2007.
[13]李云辉,张军.直齿锥齿轮参数化三维造型及加工应用.制造业信息化,2007,02:25~26.
[14]陈霞,夏巨谌,胡国安.基于UG的直齿锥齿轮的精确建模.中国机械工程,2006,17:107~110.
[15]郑威,夏巨谌等.基于UG的汽车差速器圆锥齿轮参数化造型系统的开发.机械传动,2007,04:28~30.
[16]朱可柯.直齿圆锥锥齿轮数学建模与造型技术的研究.南京:南京航空航天大学硕士论文,2004.
[17]黄翔,李迎光. UG应用开发教程与实例精解.北京:清华大学出版社,2005.
[18]侯永涛,丁向阳. UG/Open二次开发与实例精解.北京:化学工业出版社,2007.
[19]国营渭阳柴油机厂.直齿锥齿轮.北京:国防工业出版社,1978.
[20]谢海波.齿轮参数化CAD系统开发与设计.机械研究与应用,2000,7:56~59.
[21]刘惟信等.圆锥齿轮与双曲面齿轮.北京:人民交通出版社,1980.
[22]周纪良.圆拉直齿锥齿轮设计.拖拉机与农用运输车,2000,6:15~18.
[23] Hong-sen Yan, Tai-shi Lai. Geometry design of an elementary planetary gear train with cylindrical tooth-profiles, Mechanizm and Machine Theory, 2002, Volume 37.
[24] Darle W Dudley, Gear Handbook. McGRAW-Hill Book Company INC. NewYork,1962.
[25]第一汽车制造厂,南开大学齿轮啮合理论研究组.圆拉法加工直齿锥齿轮所依据的两个公式的推导(一).汽车技术,1978,4:75~79.
[26]侯昌友.直齿锥齿轮圆拉法齿轮设计中有关问题的分析和研究.汽车科技,1978,4:49~57.
[27]宋智民,李秀春.直齿锥齿轮的鼓形齿及加工方法初探.机械管理开发,2005,10:18~20.
[28]李凌丰.参数化设计中的尺寸约束传递模型研究.中国机械工程,1996,8:95~98.
[29] DeRose T, Goldman R, Hagen H,etal. Functional composition algorithms via blossoming. ACM Transactions on Graphics, 1993, 12(2):113~115.
[30]朱心雄等.自由曲线曲面造型技术.北京:科学技术出版社,2000.
[31] Seidel H P. Computing B-spline control points using polar forms. Computer Aided Design,1991,23(9):634~640.
[32] Ramshaw L. Blossoms are polar form. Computer Aided Geometric Design, 1989,6(4):323~358.
[33]张幼军,王世杰等编著. UG CAD/CAM基础教程.北京:清华大学出版社,2006.
[34]谢国明等编译. UG CAM实用教程.北京:清华大学出版社,2003.
[35] S.H.Suh. Sculptured surface machining of spiral bevel gears with CNC milling. International Journal of Machine Tools & Manufacture,2001. 41:833~850.
[36] Sarma, R., and Dutta, D., The Geometry and Generation of NC Tool Paths. Journal of Mechanical Design.1997.
[37]董正卫,田立中,付宜利. UG/OPEN API编程基础.北京:清华大学出版社,2002