基于Free-form机床的弧齿锥齿轮定摆角全工序法主动设计制造理论

Compared with the traditional “five-cut method”, “the completing process method” has significant advantages such as efficiency increase, cost reduction, machining accuracy improvement, tooth strength enhancement, and so on. Since the concave and convex flank are cut simultaneously by one cutter, the contact pattern adjustment by “the completing process method” is much more difficult than that by “the five-cut method”. This study conducts a research on the active design and manufacture of spiral bevel gear by the completing process method with fixed workpiece axis based on the Free-form type machine tool, and takes full advantage of the flexibility and freedom of the Free-form type machine tool, which is beneficial to the design and manufacture of high-performance tooth surface. First, the active design theory of tooth surface by the completing process method is established, including gear macrogeometry modification and active design of tooth surface microgeometry. Second, the completing process manufacture theory with fixed workpiece axis based on the Free-form type machine tool is established, with which the designed tooth surface and tooth depth are guaranteed theoretically, and the workpiece axis can stay fixed. Third, the tooth surface modification method aiming at the actual working conditions is established. Finally, the meshing performance rule of the point contact tooth surface by the completing process method is revealed, and the influence rule of the machining parameter error on the tooth surface topology is revealed. The primary target of this study is to improve the meshing performance of spiral bevel gear by the completing process method, and to provide technical and theoretical support for the promotion of design and manufacture level of spiral bevel gear.

“全工序法”加工弧齿锥齿轮相比传统的“五刀法”有生产效率高、成本低、加工精度高、齿轮强度高等优点。由于“全工序法”用一把刀盘同时切削凹面和凸面，所以接触区的调整比“五刀法”要困难许多。本项目对基于Free-form式机床的“定摆角”全工序法的主动设计制造理论开展研究，充分利用Free-form式机床的灵活性和自由度，设计制造出啮合性能良好的齿面。首先，建立全工序法弧齿锥齿轮的齿面主动设计理论，包括齿坯宏观参数修正和齿面微观形式的主动设计；其次，建立直接面向Free-form式机床的“定摆角”全工序法制造理论，从理论上保证加工出设计齿面的同时也加工出设计齿深，且不需要工件摆动轴参与联动；然后，建立针对实际工况的全工序法齿面修形设计方法；最后，揭示全工序法点接触齿面的啮合行为规律，揭示加工参数误差对齿面的影响规律。以期提高全工序法齿轮的啮合性能，为提升弧齿锥齿轮设计制造水平提供理论和技术支持。

随着汽车、航空和机器人等行业的高速发展，作为核心基础零部件，弧齿锥齿轮高效、高质量、低成本的设计制造理论对提升相关行业的核心竞争力有巨大的推动作用。全工序法加工弧齿锥齿轮有生产效率高、成本低、加工精度高、齿轮强度高等优点，对提升主机产品的性能、质量和可靠性起着巨大作用。但由于全工序法加工小轮是用一把刀盘同时切削凹面和凸面，机床加工运动会同时影响两面的齿面形式，所以全工序法对齿轮副啮合性能的保证约束多、难度大。.因此，本项目提出建立直接面向Free-form式CNC机床的定摆角全工序法弧齿锥齿轮的主动设计制造理论。建立了全工序法弧齿锥齿轮的齿面主动设计理论，修正了齿轮副的齿坯宏观几何参数使其适合全工序法加工方式, 主动设计小轮齿面微观形式参数以满足对齿轮副啮合性能的需求；其次，建立了直接面向Free-form式CNC机床的定摆角全工序法制造理论，获取了刀具中心的运动曲线和刀具尺寸参数；分析了错位量对接触斑点的影响规律，研究了针对齿轮副在最常用载荷下的错位量对齿面进行修形设计的方法；分析了加工参数误差对全工序法齿面的影响规律，并通过仿真和试验对提出的理论方法进行了验证，结果表明本项目提出的理论是可行的。.本项目充分利用Free-form式CNC机床的优势，加工过程中不需要工件摆动轴参与联动，避免了工件摆动轴制造困难以及运动精度难以保证带来的加工误差，从理论上保证加工出设计齿面的同时也加工出设计齿深，为提升弧齿锥齿轮设计制造水平奠定了理论基础。

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