A composite collaborative grinding method for worm grinding wheel and profiled grinding wheel gear grinding process

Abstract

The present invention provides a composite collaborative grinding method for a worm grinding wheel and a forming grinding wheel gear grinding process, comprising carrying out a composite gear grinding machine structure optimization design, specifically, simultaneously installing the worm grinding wheel and the forming grinding wheel on the grinding wheel main shaft; using a common roller dressing device according to the composite gear grinding machine main shaft structure, using the common roller dressing device to dress the composite shaft cross-sectional profile of the worm grinding wheel and the forming grinding wheel, and planning the dressing path according to the composite shaft cross-sectional profile to complete the dressing of the worm grinding wheel and the forming grinding wheel; using the worm grinding wheel to perform rough grinding on the gear, measuring the maximum grinding allowance and the minimum grinding allowance of the tooth surface after rough grinding, adjusting the automatic centering device according to the maximum grinding allowance and the minimum grinding allowance, and using the forming grinding wheel to perform fine grinding on the gear. This application enables the worm grinding wheel and the forming grinding wheel to work together in the same process, thereby simultaneously completing the rough machining and fine machining of the gear, improving production efficiency and overall machining accuracy, and reducing machining costs.

Description

Technical Field

[0001] The invention relates to the technical field of gear processing, and in particular to a composite collaborative grinding method of a worm grinding wheel and a forming grinding wheel. Background Art

[0002] Gear transmissions are widely used in the automotive, marine, and aerospace industries. Their performance and lifespan depend on the machining accuracy and surface quality of the gears. Gear grinding, as the final finishing step in gear machining, directly affects transmission errors and transmission noise. Therefore, improving the efficiency and precision of gear grinding has become a key research area in gear manufacturing.

[0003] Currently, gear grinding processes primarily include worm wheel grinding and profile wheel grinding. Worm wheel grinding utilizes a continuous rolling process, which is suitable for mass production and highly efficient. However, due to the continuity limitations of the grinding path, achieving extremely high tooth surface precision and surface quality is difficult. Profile wheel grinding, through precise profiling using a profile wheel that matches the tooth profile, can significantly improve the machining accuracy and finish of the tooth surface. However, profile wheel grinding is relatively slow, making it unsuitable for mass production and requiring a complex wheel shaping process.

[0004] Traditional gear grinding processes typically rely on a single worm wheel or profile wheel grinding process, making it difficult to meet the high-precision, low-cost, and high-efficiency demands of modern manufacturing. Composite grinding processes have become a research hotspot, but multiple clamping steps not only increase production time and introduce positioning errors, affecting the final gear machining accuracy, but also the separation of process steps leads to increased equipment usage, complex production line layout, and low overall efficiency. Therefore, a composite collaborative grinding method combining worm and profile wheel grinding processes is urgently needed to improve gear production accuracy and efficiency. Summary of the Invention

[0005] In view of the technical problem that the existing gear grinding process usually only selects a single process of worm grinding wheel grinding or formed grinding wheel grinding, which is difficult to meet the modern manufacturing requirements of high precision, low cost and high efficiency, the present invention provides a composite collaborative grinding method of worm grinding wheel and formed grinding wheel gear grinding process to achieve the technical effect of "one machine, two tasks" high-efficiency grinding.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0007] A composite collaborative grinding method for a worm grinding wheel and a profiled grinding wheel, the method comprising:

[0008] Carry out structural optimization design of composite gear grinding machine tools, specifically by installing the worm grinding wheel and the profile grinding wheel on the grinding wheel spindle at the same time;

[0009] According to the common roller dressing device of the main shaft structure of the composite gear grinding machine, the common roller dressing device is used to dress the composite shaft cross-section profile of the worm grinding wheel and the forming grinding wheel, and the dressing path is planned according to the composite shaft cross-section profile to complete the dressing of the worm grinding wheel and the forming grinding wheel;

[0010] The gear is roughly ground using the worm grinding wheel, and after rough grinding, the maximum grinding allowance and the minimum grinding allowance of the tooth surface are measured, the automatic centering device is adjusted according to the maximum grinding allowance and the minimum grinding allowance, and the gear is finely ground using the forming grinding wheel.

[0011] Furthermore, the structural optimization design of the composite gear grinding machine is specifically to simultaneously install the worm grinding wheel and the forming grinding wheel on the grinding wheel spindle, including:

[0012] To meet the needs of rapid replacement and stable clamping of worm and profile grinding wheels, the composite gear grinding machine adopts a dual-grinding-wheel spindle design. Two different grinding wheels, a worm and a profile grinding wheel, can be installed on the same grinding station. It is also equipped with an automatic grinding wheel replacement program module developed through a human-machine interface, which enables automatic switching between the worm and profile grinding wheels without removing the grinding wheels.

[0013] The automatic grinding wheel replacement program module includes grinding wheel type selection, coolant parameters, installation position and safety detection; among them, the grinding wheel type selection is to select a worm grinding wheel or a forming grinding wheel; the coolant parameters are to set the coolant flow and type to ensure the best processing effect; the installation position is to confirm the installation position and alignment status of the grinding wheel; the safety detection is to check various safety parameters including the status of the protective device.

[0014] Furthermore, the common roller dressing device is used according to the main shaft structure of the composite gear grinding machine tool, and the common roller dressing device is used to dress the composite shaft cross-sectional profile of the worm grinding wheel and the forming grinding wheel. The dressing path is planned according to the composite shaft cross-sectional profile to complete the dressing of the worm grinding wheel and the forming grinding wheel, including:

[0015] The common roller dressing device is installed on the column of the composite gear grinding machine. The common roller dressing device is used to dress the cross-sectional profile of the composite shaft of the worm grinding wheel and the profiled grinding wheel. The cross-sectional profile of the composite shaft of the worm grinding wheel and the profiled grinding wheel is calculated by the digital envelope method and is defined as follows:

[0016]

[0017] in, Indicates the position of the starting point of the i-th envelope point in the grinding wheel and tooth surface coordinate systems, Indicates the position of the end point of the i-th envelope point in the grinding wheel and tooth surface coordinate systems, M sg is the transformation matrix between the gear and grinding wheel coordinate systems, which is defined as follows:

[0018]

[0019] Among them, β and α are the rotation angle of the gear around the Z axis and the installation angle of the grinding wheel, b is the installation distance between the grinding wheel and the gear, and z m is the movement parameter, change the movement parameter z m And the grinding wheel installation angle α eventually forms a profile on the grinding wheel calculation plane;

[0020] A common roller dressing spline program is generated according to the cross-sectional profile of the composite shaft of the worm grinding wheel and the forming grinding wheel and the dressing step length, and this program is used to manually replace the dressing spline program automatically calculated and generated by the machine tool; during the grinding wheel dressing process, the motion trajectory of the common roller is always dressed from the end face of the grinding wheel to the width center of the grinding wheel.

[0021] Furthermore, when the common roller dressing device is used to dress the worm grinding wheel, a multi-step dressing method is adopted to uniformly discretize the worm grinding wheel profile. The degree of discretization is determined by the specific required dressing accuracy and is defined as follows:

[0022]

[0023] Among them, θ represents the degree of discreteness, L represents the specific dressing step size, and r represents the dressing radius of the common roller.

[0024] Furthermore, the gear is rough-ground using the worm grinding wheel, the maximum grinding allowance and the minimum grinding allowance of the tooth surface are measured after rough grinding, the automatic centering device is adjusted according to the maximum grinding allowance and the minimum grinding allowance, and the gear is fine-ground using the forming grinding wheel, including:

[0025] Grinding parameters are set according to the material, size, tooth profile requirements and surface roughness requirements of the gear. The grinding parameters include the rotation speed, feed rate, cutting depth of the worm grinding wheel and the grinding wheel linear speed, feed rate and number of strokes of the forming grinding wheel; the gear is roughly ground using the worm grinding wheel, grinding along the spiral direction of the gear to remove most of the material and preliminarily form the tooth profile; the coordinate points of the left and right tooth surfaces after grinding are measured, the absolute centering value c is determined based on the measurement point data, and the maximum grinding allowance of the left and right tooth surfaces is calculated with the minimum grinding allowance of the single-side tooth surface being 0. Cutting allowances a1 and b1, minimum grinding allowances a2 and b2, adjust the centering value to c2 according to the maximum and minimum grinding allowances for dynamic distribution of grinding allowances. If a1 ≥ b1, adjust the centering value c2 to the final centering value. If a1 < b1, the final centering value c3 = c2-a2-b2. After determining the centering value, use the automatic centering device for centering, and use the forming grinding wheel for fine grinding of the gear. The forming grinding wheel accurately trims each tooth surface of the gear according to the set tooth curve parameters to ensure the geometric accuracy and surface quality of the tooth profile.

[0026] Compared with the prior art, the composite collaborative grinding method of the worm grinding wheel and the profiled grinding wheel provided by the present invention has the following advantages:

[0027] 1. The worm grinding wheel and the profile grinding wheel work together in the same process to complete the roughing and finishing of the gear at the same time. The worm grinding wheel can remove materials efficiently, while the profile grinding wheel can perform precise tooth profile dressing, shortening the processing time and improving production efficiency.

[0028] 2. The worm grinding wheel is used for preliminary grinding to remove most of the material and reduce the errors generated during rough machining; while the forming grinding wheel is used for final finishing to achieve higher precision and surface quality of the gear tooth surface; the composite grinding process reduces the superposition of gear machining errors and improves the overall machining accuracy.

[0029] 3. The composite collaborative grinding method can complete multiple processing processes in one processing step, reducing the number of tool changes and process conversion time, improving production continuity, and reducing equipment and tool wear.

[0030] 4. The present invention can be applied to the processing of gears of different specifications, shapes and materials. By adjusting the parameters of the worm grinding wheel and the forming grinding wheel, it can flexibly respond to the processing requirements of various gears. Specifically, it can be applied to the grinding of straight teeth and helical teeth, and can adapt to the processing needs of various gear types.

[0031] 5. Since this process can improve efficiency, reduce tool wear and tool changes, and reduce the probability of rework and correction, it can reduce overall processing costs. This cost advantage is more significant in large-scale production. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of a composite gear grinding machine tool of a worm grinding wheel and a formed grinding wheel provided by the present invention.

[0033] Figure 2 It is a meshing coordinate system diagram of the grinding wheel and the gear provided by the present invention.

[0034] Figure 3 This is a grinding allowance distribution flow chart provided by the present invention.

[0035] In the figure, 1. worm grinding wheel; 2. forming grinding wheel; 3. roller dressing device. DETAILED DESCRIPTION

[0036] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below with reference to specific illustrations.

[0037] Please refer to Figure 1As shown, the present invention provides a composite collaborative grinding method of a worm grinding wheel and a profiled grinding wheel, the method comprising:

[0038] Carry out structural optimization design of composite gear grinding machine tools, specifically by simultaneously installing the worm grinding wheel 1 and the forming grinding wheel 2 on the grinding wheel spindle;

[0039] According to the common roller dressing device 3 of the main shaft structure of the composite gear grinding machine, the common roller dressing device 3 is used to dress the composite shaft cross-sectional profile of the worm grinding wheel and the forming grinding wheel, and the dressing path is planned according to the composite shaft cross-sectional profile to complete the dressing of the worm grinding wheel and the forming grinding wheel; wherein, the roller dressing device 3 is an existing dressing device provided with the machine tool itself, which previously could only dress the worm grinding wheel 1 or the forming grinding wheel 2, but now serves as a common dressing device for the worm grinding wheel 1 and the forming grinding wheel 2;

[0040] The gear is roughly ground using the worm grinding wheel, and after rough grinding, the maximum grinding allowance and the minimum grinding allowance of the tooth surface are measured, the automatic centering device is adjusted according to the maximum grinding allowance and the minimum grinding allowance, and the gear is finely ground using the forming grinding wheel.

[0041] As a specific embodiment, the structural optimization design of the composite gear grinding machine is specifically to simultaneously install the worm grinding wheel and the forming grinding wheel on the grinding wheel spindle, including:

[0042] To meet the needs of rapid replacement and stable clamping of worm and profile grinding wheels, the composite gear grinding machine adopts a dual-grinding-wheel spindle design. Two different grinding wheels, a worm and a profile grinding wheel, can be installed on the same grinding station. It is also equipped with an automatic grinding wheel replacement program module developed through a human-machine interface, which enables automatic switching between the worm and profile grinding wheels without removing the grinding wheels.

[0043] The automatic grinding wheel replacement program module includes grinding wheel type selection, coolant parameters, installation position and safety detection; among them, the grinding wheel type selection is to select a worm grinding wheel or a forming grinding wheel; the coolant parameters are to set the coolant flow and type to ensure the best processing effect; the installation position is to confirm the installation position and alignment status of the grinding wheel; the safety detection is to check various safety parameters including the status of the protective device.

[0044] As a specific example, please refer to Figure 2 As shown, the common roller dressing device according to the main shaft structure of the composite gear grinding machine tool is used to dress the composite shaft cross-sectional profile of the worm grinding wheel and the forming grinding wheel using the common roller dressing device, and the dressing path is planned according to the composite shaft cross-sectional profile to complete the dressing of the worm grinding wheel and the forming grinding wheel, including:

[0045] The common roller dressing device is installed on the small column of the composite gear grinding machine. The common roller dressing device is used to dress the cross-sectional profile of the composite shaft of the worm grinding wheel and the profiled grinding wheel. The cross-sectional profile of the composite shaft of the worm grinding wheel and the profiled grinding wheel is calculated by the digital envelope method and is defined as follows:

[0046]

[0047] in, Indicates the position of the starting point of the i-th envelope point in the grinding wheel and tooth surface coordinate systems, Indicates the position of the end point of the i-th envelope point in the grinding wheel and tooth surface coordinate systems, M sg is the transformation matrix between the gear and grinding wheel coordinate systems, which is defined as follows:

[0048]

[0049] Among them, β and α are the rotation angle of the gear around the Z axis and the installation angle of the grinding wheel, b is the installation distance between the grinding wheel and the gear, and z m is the movement parameter, change the movement parameter z m And the grinding wheel installation angle α eventually forms a profile on the grinding wheel calculation plane;

[0050] A common roller dressing spline program is generated according to the cross-sectional profile of the composite shaft of the worm grinding wheel and the forming grinding wheel and the dressing step length, and this program is used to manually replace the dressing spline program automatically calculated and generated by the machine tool; during the grinding wheel dressing process, the motion trajectory of the common roller is always dressed from the end face of the grinding wheel to the width center of the grinding wheel.

[0051] As a specific embodiment, when the common roller dressing device is used to dress the worm grinding wheel, a multi-step dressing method is adopted to uniformly discretize the worm grinding wheel profile. The degree of discretization is determined by the specific required dressing accuracy and is defined as follows:

[0052]

[0053] Among them, θ represents the degree of discreteness, L represents the specific dressing step size, and r represents the dressing radius of the common roller.

[0054] As a specific example, please refer to Figure 3 As shown, the gear is roughly ground using the worm grinding wheel, the maximum grinding allowance and the minimum grinding allowance of the tooth surface are measured after rough grinding, the automatic centering device is adjusted according to the maximum grinding allowance and the minimum grinding allowance, and the gear is finely ground using the forming grinding wheel, including:

[0055] Set the grinding parameters according to the material, size, tooth profile requirements and surface roughness requirements of the gear. The grinding parameters include the rotational speed of the worm grinding wheel, the feed speed, the cutting depth, and the grinding wheel linear speed, feed speed, and number of strokes of the form grinding wheel. Use the worm grinding wheel to rough grind the gear, grinding along the helical direction of the gear to remove most of the material and preliminarily form the tooth profile. Measure the coordinate points of the left and right tooth surfaces after grinding at the pitch circle position, judge the absolute centering value c according to the measured point data, and calculate the maximum grinding allowances a1 and b1, and minimum grinding allowances a2 and b2 of the left and right tooth surfaces with the minimum grinding allowance of one side tooth surface, such as the left tooth surface, being 0. Adjust the centering value to c2 for dynamic distribution of the grinding allowance. If a1≥b1 (that is, the maximum grinding allowance of the left tooth surface is greater than or equal to the maximum grinding allowance of the right tooth surface), then adjust the centering value c2 to the final centering value, that is, c3 = c2; if a1 < b1 (that is, the maximum grinding allowance of the left tooth surface is less than the maximum grinding allowance of the right tooth surface), then the final centering value c3 = c2 - a2 - b2. After determining the centering value, use the existing automatic centering device自带 by the machine tool itself for centering (essentially, after measurement, control the movement of the machine tool axis through the existing numerical control program). Use the form grinding wheel to finish grind the gear. The form grinding wheel precisely trims each tooth surface of the gear according to the set tooth profile curve parameters to ensure the geometric accuracy and surface quality of the tooth profile.

[0056] Compared with the prior art, the worm grinding wheel and form grinding wheel gear grinding process composite collaborative grinding method provided by the present invention has the following advantages:

[0057] 1. The worm grinding wheel and the form grinding wheel work together in the same process, and can simultaneously complete the rough machining and finish machining of the gear. The worm grinding wheel can efficiently remove materials, while the form grinding wheel can perform precise tooth profile trimming, shortening the processing time and improving the production efficiency.

[0058] 2. The worm grinding wheel is used for preliminary grinding to remove most of the materials and reduce the errors generated in the rough machining process; while the form grinding wheel is used for the final finish machining to make the gear tooth surface reach higher precision and surface quality; the composite grinding process reduces the superposition of gear machining errors and improves the overall machining precision.

[0059] 3. The composite collaborative grinding method can complete multiple processing processes in one processing step, reducing the number of tool changes and process conversion time, improving the continuity of production, and reducing the wear of the equipment and tools.

[0060] 4. The present invention can be applied to the machining of gears with different specifications, shapes and materials. By adjusting the parameters of the worm grinding wheel and the form grinding wheel, it can flexibly meet the machining requirements of various gears. Specifically, it can be applied to the grinding of spur gears and helical gears, and can adapt to the machining requirements of various gear types.

[0061] 5. Since this process can improve efficiency, reduce tool wear and tool changes, and reduce the probability of rework and correction, it can reduce overall processing costs. This cost advantage is more significant in large-scale production.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A composite collaborative grinding method for worm grinding wheel and profile grinding wheel, characterized in that: The method comprises: Carry out structural optimization design of composite gear grinding machine tools, specifically by installing the worm grinding wheel and the profile grinding wheel on the grinding wheel spindle at the same time; According to the common roller dressing device of the main shaft structure of the composite gear grinding machine, the common roller dressing device is used to dress the composite shaft cross-section profile of the worm grinding wheel and the forming grinding wheel, and the dressing path is planned according to the composite shaft cross-section profile to complete the dressing of the worm grinding wheel and the forming grinding wheel; Rough grinding the gear using the worm grinding wheel, measuring the maximum grinding allowance and the minimum grinding allowance of the tooth surface after rough grinding, adjusting the automatic centering device according to the maximum grinding allowance and the minimum grinding allowance, and fine grinding the gear using the forming grinding wheel; The method comprises the following steps: rough grinding the gear by using the worm grinding wheel, measuring the maximum grinding allowance and the minimum grinding allowance of the tooth surface after rough grinding, adjusting the automatic centering device according to the maximum grinding allowance and the minimum grinding allowance, and fine grinding the gear by using the forming grinding wheel. Grinding parameters are set according to the material, size, tooth profile requirements and surface roughness requirements of the gear. The grinding parameters include the rotation speed, feed rate, cutting depth of the worm grinding wheel and the grinding wheel linear speed, feed rate and number of strokes of the forming grinding wheel; the gear is roughly ground using the worm grinding wheel, grinding along the spiral direction of the gear to remove most of the material and preliminarily form the tooth profile; the coordinate points of the left and right tooth surfaces after grinding are measured, the absolute centering value c is determined based on the measurement point data, and the maximum grinding allowance of the left and right tooth surfaces is calculated with the minimum grinding allowance of the single-side tooth surface being 0. Cutting allowances a1 and b1, minimum grinding allowances a2 and b2, adjust the centering value to c2 according to the maximum and minimum grinding allowances for dynamic distribution of grinding allowances. If a1 ≥ b1, adjust the centering value c2 to the final centering value. If a1 < b1, the final centering value c3 = c2-a2-b2. After determining the centering value, use the automatic centering device for centering, and use the forming grinding wheel for fine grinding of the gear. The forming grinding wheel accurately trims each tooth surface of the gear according to the set tooth curve parameters to ensure the geometric accuracy and surface quality of the tooth profile.

2. The composite collaborative grinding method of the worm grinding wheel and the profiled grinding wheel according to claim 1 is characterized in that: The structural optimization design of the composite gear grinding machine is specifically to simultaneously install the worm grinding wheel and the forming grinding wheel on the grinding wheel spindle, including: To meet the needs of rapid replacement and stable clamping of worm and profile grinding wheels, the composite gear grinding machine adopts a dual-grinding-wheel spindle design. Two different grinding wheels, a worm and a profile grinding wheel, can be installed on the same grinding station. It is also equipped with an automatic grinding wheel replacement program module developed through a human-machine interface, which enables automatic switching between the worm and profile grinding wheels without removing the grinding wheels. The automatic grinding wheel replacement program module includes grinding wheel type selection, coolant parameters, installation position and safety detection; among them, the grinding wheel type selection is to select a worm grinding wheel or a forming grinding wheel; the coolant parameters are to set the coolant flow and type to ensure the best processing effect; the installation position is to confirm the installation position and alignment status of the grinding wheel; the safety detection is to check various safety parameters including the status of the protective device.

3. The composite collaborative grinding method of a worm grinding wheel and a profiled grinding wheel according to claim 1, characterized in that: The common roller dressing device according to the main shaft structure of the composite gear grinding machine tool is used to dress the composite shaft cross-sectional profile of the worm grinding wheel and the forming grinding wheel using the common roller dressing device, and the dressing path is planned according to the composite shaft cross-sectional profile to complete the dressing of the worm grinding wheel and the forming grinding wheel, including: The common roller dressing device is installed on the column of the composite gear grinding machine. The common roller dressing device is used to dress the cross-sectional profile of the composite shaft of the worm grinding wheel and the profiled grinding wheel. The cross-sectional profile of the composite shaft of the worm grinding wheel and the profiled grinding wheel is calculated by the digital envelope method and is defined as follows: in, Indicates the position of the starting point of the i-th envelope point in the grinding wheel and tooth surface coordinate systems, Indicates the position of the end point of the i-th envelope point in the grinding wheel and tooth surface coordinate systems, M sg is the transformation matrix between the gear and grinding wheel coordinate systems, which is defined as follows: Among them, β and α are the rotation angle of the gear around the Z axis and the installation angle of the grinding wheel, b is the installation distance between the grinding wheel and the gear, and z m is the movement parameter, change the movement parameter z m And the grinding wheel installation angle α eventually forms a profile on the grinding wheel calculation plane; A common roller dressing spline program is generated according to the cross-sectional profile of the composite shaft of the worm grinding wheel and the forming grinding wheel and the dressing step length, and this program is used to manually replace the dressing spline program automatically calculated and generated by the machine tool; during the grinding wheel dressing process, the motion trajectory of the common roller is always dressed from the end face of the grinding wheel to the width center of the grinding wheel.

4. The composite collaborative grinding method of a worm grinding wheel and a profiled grinding wheel according to claim 3, characterized in that: When using the common roller dressing device to dress the worm grinding wheel, a multi-step dressing method is adopted to uniformly discretize the worm grinding wheel profile. The degree of discretization is determined by the specific required dressing accuracy and is defined as follows: Among them, θ represents the degree of discreteness, L represents the specific dressing step size, and r represents the dressing radius of the common roller.

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