Design method of full-life diamond roller for powerful inner honing wheel

Abstract

The invention provides a design method of a full-life diamond roller for a powerful inner honing wheel. The design method comprises the steps that design parameters of the diamond roller are determined according to parameters of an outer gear and the inner honing wheel; the design parameters of the diamond roller comprise a normal modulus Mn, a circle dividing normal pressure angle Afn, a helix angle Bf2, a tooth number Z2, a displacement coefficient Xn2, an addendum circle diameter Deg2, a root circle diameter Dig2 and an effective starting circle diameter dyx2; and calculating the addendum circle diameter and addendum width of the diamond roller. According to the parameters of the new inner honing wheel and the old inner honing wheel, design parameters of the two sets of diamond rollers are determined respectively, and then the design parameters of the full-life diamond roller are obtained through intersection; the tooth crest width of the diamond roller is checked, it is guaranteed that the tooth crest does not become sharp, parameters of the diamond roller are optimized, the optimality of the honing process is guaranteed, the diamond roller is designed only in 20 minutes at present, and compared with dozens of hours in the prior art, efficiency is greatly improved, and the new product development period is shortened.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of gear honing design of new energy, and particularly relates to a design method of a full-life diamond roller for a strong internal honing wheel. BACKGROUND

[0002] Gear honing is a hard tooth surface finishing technology. In order to reduce the meshing noise of high-speed gear pairs in new energy vehicles, the manufacturing precision of gear products needs to be improved and the processing texture of the gear meshing surface needs to be improved. The internal honing wheel is precisely shaped by using a gear type diamond shaping roller, which can significantly improve the honing processing precision and is not easy to cause tooth surface burn and cracks. A processing surface with fine cutting texture and low surface roughness value can be obtained. Therefore, this strong internal honing process has recently been popularized and used in the finishing of domestic new energy high-speed gears.

[0003] The gear type diamond roller can precisely shape the strong internal honing wheel. The design and manufacturing errors of the diamond roller are transmitted and amplified to the workpiece through the roller and the honing wheel. The shaping method of the internal honing wheel by the diamond roller is as follows: the involute surface of the diamond roller tooth surface is taken as the parent surface, the tooth surface of the internal honing wheel is enveloped, and then the tooth surface of the workpiece is processed by using the tooth surface of the internal honing wheel. The diamond roller simultaneously trims the tooth surface and tooth root of the honing wheel. The design and manufacturing precision of the diamond roller directly affects the final precision of the honing wheel and the gear.

[0004] In the prior art, the main problems existing in the design and manufacturing technology of the diamond roller are as follows:

[0005] (1) The matching relationship of the new and old honing wheels and the diamond roller during the full life is not considered as a whole, which affects the service life of the diamond roller and the honing wheel.

[0006] (2) The parameters of the diamond roller are not optimized, which cannot guarantee the optimality of the honing process, and affects the processing quality, efficiency and cost of the gear.

[0007] (3) There is no complete and independent method for accurately designing the parameters of the diamond roller, which leads to a long development cycle and high cost of new products. SUMMARY

[0008] Therefore, the present application provides a design method of a full-life diamond roller for a strong internal honing wheel, so as to solve the technical problems that the matching relationship of the new and old honing wheels and the diamond roller during the full life is not considered as a whole, the parameters of the diamond roller are not optimized, the optimality of the honing process cannot be guaranteed, and the development cycle of new products is long and the cost is high.

[0009] The technical scheme of the present application is as follows:

[0010] The application provides a design method of a full-life diamond roller for a strong internal honing wheel, the diamond roller is engaged with an internal crossed gear pair of the internal honing wheel, and the design method comprises the following steps:

[0011] determining design parameters of the diamond roller according to parameters of the external gear and the internal honing wheel; the design parameters of the diamond roller comprise a normal modulus Mn, a normal pressure angle Afn of a division circle, a helix angle Bf2, a tooth number Z2, a modification coefficient Xn2, a dedendum circle diameter Deg2, a tooth root circle diameter Dig2 and an effective starting circle diameter dyx2;

[0012] calculating the dedendum circle diameter of the diamond roller according to an effective involute termination point diameter of the internal honing wheel, and checking the dedendum width of the diamond roller to ensure that the dedendum is not pointed;

[0013] determining design parameters of two groups of diamond rollers according to parameters of a new internal honing wheel and an old internal honing wheel respectively, taking the intersection of the design parameters of the two groups of diamond rollers to obtain the design parameters of the full-life diamond roller.

[0014] On the basis of the above technical scheme, preferably, the design parameters of the diamond roller are determined according to the parameters of the external gear and the internal honing wheel, comprising the following steps:

[0015] the normal modulus Mn, the helix angle Bf2 and the normal pressure angle Afn of the diamond roller are the same as those of the internal honing wheel;

[0016] the modification coefficient Xn2 and the tooth number Z2 of the diamond roller are determined according to the modification coefficient Xn of the external gear to be honed by the internal honing wheel and the tooth number Z1 of the internal honing wheel respectively;

[0017] the normal pitch circle engagement angle ajn of the diamond roller and the internal honing wheel is calculated:

[0018] the initial normal pitch circle engagement angle ajn=Afn+v, wherein v is a coefficient for converting an angle into an arc, and v is π / 180;

[0019] an iteration function fajn of the normal pitch circle engagement angle ajn is established, and the normal pitch circle engagement angle ajn is iterated: when the value of the iteration function is less than a set threshold, the pitch circle end surface engagement angles ajt11 and ajt21 are calculated according to the current value of the normal pitch circle engagement angle ajn.

[0020] On the basis of the above technical scheme, preferably, the design parameters of the diamond roller are determined according to the parameters of the external gear and the internal honing wheel, comprising the following steps:

[0021] the dedendum circle Deg2 of the diamond roller is calculated according to the small diameter De1, the pitch circle diameter Dj1 and the large diameter expansion coefficient Cn1 of the internal honing wheel in the gap-free engagement;

[0022] According to the major diameter Di1 of the inner honing wheel when there is no gap engagement, the pitch circle diameter Dj1 and the minor diameter expansion coefficient Cn2, the dedendum circle diameter Dig2 of the diamond roller is calculated;

[0023] According to the actual engagement line length ga, the major diameter Di1, the base circle diameter d01 and the base circle helix angle B01 of the inner honing wheel, and the base circle helix angle B02 and the base circle diameter d02 of the diamond roller, the effective termination circle diameter dyx2 of the diamond roller is calculated.

[0024] On the basis of the above technical scheme, preferably, the tooth top width of the diamond roller is calculated to ensure that the tooth top is not pointed, comprising: calculating the tooth top width Seng2 of the diamond roller, and determining that the tooth top of the diamond roller is not pointed when the tooth top width Seng2 of the diamond roller is greater than or equal to 0.30 mm.

[0025] On the basis of the above technical scheme, preferably, the tooth top width Seng2 of the diamond roller is calculated, comprising: according to the normal circular arc tooth thickness sfn2 of the diamond roller, the base circle diameter d02, the tooth top circle diameter Deg2, the helix angle Bf2, the division circle diameter Df2 and the involute function invaft2, the tooth top width Seng2 of the diamond roller is calculated.

[0026] On the basis of the above technical scheme, preferably, it further comprises: according to the actual engagement line length ga, the base circle helix angle B01 and the base circle diameter d01 of the inner honing wheel, and the tooth top circle diameter Deg2, the base circle diameter d02 and the base circle helix angle B02 of the diamond roller, the tooth top circle diameter Deg2 of the diamond roller and the effective involute termination point diameter dyz11 of the inner honing wheel are calculated.

[0027] On the basis of the above technical scheme, preferably, it further comprises: according to the actual engagement line length ga, the effective termination circle diameter dyz1, the base circle diameter d01 and the base circle helix angle B01 of the inner honing wheel, and the base circle diameter d02 and the base circle helix angle B02 of the diamond roller, the effective termination circle diameter dyz2 of the diamond roller is calculated.

[0028] On the basis of the above technical scheme, preferably, it further comprises: according to the pitch circle diameter Dj1 of the inner honing wheel and the pitch circle diameter Dj2 of the diamond roller, the center distance A12 when the diamond roller and the inner honing wheel are engaged without gap is calculated.

[0029] On the basis of the above technical scheme, preferably, it further comprises: according to the base circle helix angle B01 and the division circle end face pressure angle Aft1 of the inner honing wheel, and the base circle helix angle B02 and the division circle end face pressure angle Aft2 of the diamond roller, the shaft intersection angle ∑ when the diamond roller and the inner honing wheel are engaged without gap is calculated.

[0030] On the basis of the above technical scheme, preferably, it further comprises: according to the normal circular division pressure angle Afn of the diamond roller, the normal nodal circle meshing angle ajn of the inner honing roller, the normal circular arc tooth thickness sfn2, the normal modulus Mn, the tooth number Z2, the circular division end face pressure angle Aft2 and the nodal circle end face meshing angle ajt21 of the inner honing roller, the nodal circle tooth thickness sjn2 of the diamond roller is calculated.

[0031] The design method of the full-life diamond roller for the strong inner honing roller has the following beneficial effects compared with the prior art:

[0032] (1) According to the parameters of the new inner honing roller and the old inner honing roller, the design parameters of the two groups of diamond rollers are determined respectively, the intersection of the design parameters of the two groups of diamond rollers is taken, and the design parameters of the full-life diamond roller are obtained; the tooth tip width of the diamond roller is checked to ensure that the tooth tip is not sharp, the diamond roller parameters are optimized, the optimality of the honing process is ensured, and now the design of the diamond roller only takes twenty minutes, compared with the prior art which needs dozens of hours according to experience, the efficiency is at least improved by more than ten times, the new product development cycle is shortened, and the cost is reduced;

[0033] (2) The initial normal nodal circle meshing angle ajn is determined by the initial normal nodal circle meshing angle ajn=Afn+v, the iteration function fajn of the normal nodal circle meshing angle ajn is established, and the normal nodal circle meshing angle ajn is iterated: when the value of the iteration function is less than the set threshold value, the nodal circle end face meshing angles ajt11 and ajt21 are calculated according to the current value of the normal nodal circle meshing angle ajn, and the diamond roller parameters are further optimized through the above iteration operation to ensure the optimality of the honing process;

[0034] (3) The tooth tip circle Deg2 of the diamond roller is calculated according to the small diameter De1, the nodal circle diameter Dj1 and the large diameter expansion coefficient Cn1 of the inner honing roller in the gap-free meshing, the dedendum diameter Dig2 of the diamond roller is calculated according to the large diameter Di1, the nodal circle diameter Dj1 and the small diameter expansion coefficient Cn2 of the inner honing roller in the gap-free meshing, the large diameter of the diamond roller and the inner honing roller is increased by Cn1*Mn, and the small diameter of the diamond roller is reduced by Cn2*Mn, and the diamond roller parameters are optimized;

[0035] (4) When the tooth tip width of the diamond roller is greater than or equal to 0.30mm, it is determined that the tooth tip of the diamond roller is not sharp, and after calculating the tooth tip width of the broken diamond roller, it is determined that it is not less than 0.30mm, so as to ensure that the tooth tip of the diamond roller is not sharp, and the parameter design reliability of the diamond roller is improved. BRIEF DESCRIPTION OF DRAWINGS

[0036] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description only show some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained from these drawings without any creative effort.

[0037] Fig. 1 A flow chart of a design method of a full-life diamond roller for a strong internal honing wheel in an embodiment of the present application;

[0038] Fig. 2 A structural schematic diagram of an internal honing wheel dressed by a diamond roller in an embodiment of the present application;

[0039] Fig. 3 A schematic diagram of a calculation result obtained by the design method of a full-life diamond roller for a strong internal honing wheel in an embodiment of the present application. DETAILED DESCRIPTION

[0040] The technical solutions in the embodiments of the present application will be clearly and completely described in combination with the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without any creative effort fall within the scope of protection of the present application.

[0041] Referring to Figs. 1-3 The embodiment of the present application provides a design method of a full-life diamond roller for a strong internal honing wheel, the diamond roller is engaged with an internal gear pair of the internal honing wheel, and the design method comprises the following steps:

[0042] Step S1: determining design parameters of the diamond roller according to parameters of an external gear and the internal honing wheel; the design parameters of the diamond roller comprise a normal modulus Mn, a normal pressure angle of division Afn, a helix angle Bf2, a tooth number Z2, a modification coefficient Xn2, a dedendum diameter Dig2, a tooth top circle diameter Deg2 and an effective starting circle diameter dyx2;

[0043] Step S2: calculating the tooth top circle diameter of the diamond roller according to an effective involute termination point diameter of the internal honing wheel, and checking the tooth top width of the diamond roller to ensure that the tooth top is not pointed;

[0044] Step S3: determining design parameters of two groups of diamond rollers respectively according to parameters of a new internal honing wheel and an old internal honing wheel, taking the intersection of the design parameters of the two groups of diamond rollers to obtain the design parameters of a full-life diamond roller.

[0045] The design method of the full-life diamond roller for the high-strength internal honing wheel proposed in this embodiment determines the design parameters of two groups of diamond rollers according to the parameters of the new internal honing wheel and the old internal honing wheel respectively, takes the intersection of the design parameters of the two groups of diamond rollers to obtain the design parameters of the full-life diamond roller; checks the tooth tip width of the diamond roller to ensure that the tooth tip does not become sharp, optimizes the parameters of the diamond roller, ensures the optimality of the honing process, and now it only takes twenty minutes to design the diamond roller. Compared with the prior art that requires dozens of hours according to experience design, the efficiency is increased by at least more than ten times, shortening the new product development cycle and reducing the cost.

[0046] Before calculation, first list the known parameters of the external gear honed by the internal honing wheel and the new and old internal honing wheels:

[0047] In this embodiment, the parameters of the external gear honed by the internal honing wheel are as follows: the normal module is 2.4552, the number of teeth is 21, the normal pressure angle at the pitch circle is 16.5°, the helix angle is 33°, right-handed, the major diameter is 70.6, the minor diameter is 55.472, the effective termination circle diameter d y = 58, and the modification coefficient X n is 0.4553.

[0048] The parameters of the designed new and old internal honing wheels are as follows:

[0049]

[0050] In step S1, determining the design parameters of the diamond roller according to the parameters of the external gear and the internal honing wheel specifically includes:

[0051] Step S101: Select the modification coefficient X n2 of the diamond roller according to the modification coefficient X n of the gear:

[0052] X n2 = X n - △X, △X = (0.05 - 0.10), here △X takes 0.075, X n2 = 0.4553 - 0.075 = 0.38;

[0053] Determine the number of teeth Z2 of the diamond roller according to the number of teeth Z1 of the internal honing wheel respectively. Z2 < Z1 - 10, Z2 is relatively prime to Z1 and has no common divisor with the number of teeth of the internal honing wheel. The number of teeth of the external gear to be honed can be taken, Z2 = 21.

[0054] Step S102: Calculate the basic geometric parameters of the internal honing wheel and the diamond roller:

[0055] For the new honing wheel, M n = 2.4552, A f n = 16.5°, B f1 = 46.4382°, B f2 = 33°, X n1 = 0.5833, D e1 = 178.4, D i1 = 193.367, d yz1 = 188.764;

[0056] Old honing wheel Mn = 2.4552, Afn = 16.5°, Bfl = 48.1149°, Bf2 = 33°, Xnl = -0.1575, Del = 187.9, Dil = 203.754, dyzl = 200.293; the following calculations are based on the parameters of the old honing wheel:

[0057] The coefficient V = π / 180 = 0.01745329252 for converting angle to radian

[0058] Pressure angle of the dividing end face

[0059] Inner honing wheel Aftl = Atn(tan(Afn) / cos(Bfl) = Atn(tan(16.5*v) / cos(48.1*v)) = 0.4176

[0060] Diamond roller Aft2 = Atn(tan(Afn) / cos(Bf2)) = Atn(tan(16.5*v) / cos(33*v)) = 0.3395

[0061] Involute function

[0062] Inner honing wheel invaftl = tan(Aftl)-Aftl = 0.02609307

[0063] Diamond roller invaft2 = tan(Aft2)-Aft2 = 0.0136766

[0064] Dividing diameter

[0065] Dfl = Mn / cos(Bfl)*Zl = 2.4552 / cos(48.1149*v)*53 = 194.9041

[0066] Df2 = Mn / cos(Bf2)*Z2 = 2.4552 / cos(33*v)*21 = 61.4773

[0067] Base circle diameter

[0068] dOl = Dfl*cos(Aftl) = 194.9041*cos(0.41758) = 178.1566

[0069] d02 = Df2*cos(Aft2) = 61.4773*cos(0.3395175) = 57.9679

[0070] Base circle spiral angle

[0071] B01 = Atn(tan(Bf1) * cos(Aft1)) = Atn(tan(48.1149 * v) * cos(0.41578)) = 0.794948

[0072] B02 = Atn(tan(Bf2) * cos(Aft2)) = Atn(tan(33 * v) * cos(0.3395175)) = 0.549441.

[0073] Step S103: Calculate the normal circular-arc tooth slot width sfn1 of the internal honing wheel: sfn1 = Mn * pi / 2 - 2 * Xn1 * Mn * tan(Afn) = 2.4552 * 3.1415926 / 2 - 2 * (-0.1575) * 2.4552 * tan(16.5 * v) = 4.0857.

[0074] Step S104: Calculate the normal circular-arc tooth thickness sfn2 of the diamond roller: sfn2 = Mn * pi / 2 + 2 * Mn * Xn2 * tan(Afn) = 2.4552 * 3.1415926 / 2 - 2 * 0.38 * 2.4552 * tan(16.5 * v) = 4.4093.

[0075] Step S105: Calculate the normal pitch circle meshing angle ajn of the diamond roller and the internal honing wheel:

[0076] The initial pitch circle meshing angle ajn = Afn + v = 16.5 * v + v = 0.3054326;

[0077] The pitch circle end surface meshing angle ajt11 of the internal honing wheel = arcsin(sin(ajn) / cos(B01)) = 0.443808569; invajt11 = tan(ajt11) - ajt11 = 0.031633; The pitch circle end surface meshing angle ajt21 of the diamond roller = arcsin(sin(ajt11) * cos(B01) / cos(B02)) = 0.3603514;

[0078] invajt21 = tan(ajt21) - ajt21 = 0.0164527;

[0079] Establish the iteration function fajn of the normal pitch circle meshing angle ajn:

[0080] fajn = sfn1 + Mn * (Z1 * invaft1 - Z2 * invaft2) + Mn * (Z2 * invajt21 - Z1 * invajt11) - sfn2;

[0081] ajn = ajn + fajn * 0.01;

[0082] After several automatic iterative operations, when fajn<0.0000001 is satisfied, the normal meshing angle of the pitch circle ajn=0.2769217 at this time is obtained, and the following parameters are calculated through the ajn value:

[0083] ajt11=0.401050863, invajt11=0.022981616;

[0084] ajt21=0.32634173, invajt21=0.01210076;

[0085] The pitch circle tooth groove width of the inner honing wheel is calculated:

[0086] sjn1=cos(Afn) / cos(ajn)*(sfn1+Mn*Z1*(invaft1-invajt11))=4.4762;

[0087] The pitch circle tooth thickness of the diamond roller is calculated:

[0088] sjn2=cos(Afn) / cos(ajn)*(sfn2+Mn*Z2*(invaft2-invajt21))=4.4762.

[0089] Step S106: Calculate the pitch circle diameter when there is no gap meshing:

[0090] The inner honing wheel Dj1=d01 / cos(ajt11)=178.1566 / cos(0.401050863)=193.5115;

[0091] The diamond roller Dj2=d02 / cos(ajt21)=57.9679 / cos(0.32634173)=61.1978.

[0092] Step S107: Calculate the center distance A12 when the inner honing wheel and the diamond roller are gaplessly meshed:

[0093] A12=(Dj1-Dj2) / 2=(193.5115-61.1978) / 2=66.1568.

[0094] Step S108: Calculate the shaft intersection angle ∑ when the diamond roller and the inner honing wheel are gaplessly meshed:

[0095] Bj1=Atn(Tan(B01) / cos(Aft1))=0.8397634

[0096] Bj2=Atn(Tan(B02) / cos(Aft2))=0.5759586

[0097] ∑ = (Bj1 - Bj2) / v = (0.8397634 - 0.5759586) / v = 15.1149°

[0098] Step S109: calculate the dedendum diameter Dig2 of the diamond roller and the addendum diameter Deg2 (calculated according to the center distance when there is no gap) of the diamond roller:

[0099] Deg2 = Round(De1 - Dj1 + Dj2 + Cn1 * Mn * 2, 3) = 71.195;

[0100] In the formula, De1 is the small diameter of the internal grinding wheel, Cn1 is the large diameter expansion coefficient, and is -0.05;

[0101] The Round function is a rounding function, and several digits after the decimal point are taken. In this embodiment, three digits after the decimal point of the calculation result of the formula De1 - Dj1 + Dj2 + Cn1 * Mn * 2 are taken;

[0102] Dig2 = Round(Di1 - Dj1 + Dj2 - Cn2 * Mn * 2, 3) = 54.015;

[0103] In the formula, Di1 is the large diameter of the internal grinding wheel, and Cn2 is the small diameter expansion coefficient, which is 0.32.

[0104] In this step S109, the large diameter of the diamond roller and the internal grinding wheel is increased by Cn1 * Mn, and the small diameter of the diamond roller is reduced by Cn2 * Mn, thereby optimizing the parameters of the diamond roller.

[0105] Step S110: calculate the effective starting circle diameter dyx2 of the diamond roller:

[0106] The relationship between the addendum Di1 of the internal grinding wheel and the effective involute starting point diameter dyx2 of the diamond roller is as follows:

[0107] pi1 = Sqr(Di1^2 / 4 - d01^2 / 4) = 29.8606;

[0108] The Sqr function is a square root of a number;

[0109] ρyx2 = (-ga + pi1 / cos(B01)) * cos(B02) = 19.5413;

[0110] In the formula, ga is the actual length of the meshing line, and is 42.433;

[0111] dyx2 = Sqr(ρyx2^2 * 4 + d02^2) = 57.969;

[0112] The relationship between the addendum Deg2 of the diamond roller and the effective involute end point diameter dyz11 of the inner honing roller is as follows:

[0113] ρe2=Sqr(Deg2^2 / 4-d02^2 / 4)=20.6667;

[0114] ρyz11=(ga+ρe2 / cos(B02))*cos(B01)=46.6879;

[0115] dyz11=Sqr(ρyz11^2*4+d01^2)=201.1438.

[0116] Step S111: Calculate the effective end point diameter dyz2 of the diamond roller:

[0117] ρZ1=Sqr(dyz1^2 / 4-d01^2 / 4)=45.7638;

[0118] ρyz2=(-ga+ρZ1 / cos(B01))*cos(B02)=19.5413;

[0119] dyz2=Sqr(ρyz2^2*4+d02^2)=69.9086.

[0120] Step S112: Check whether the addendum width Seng2 of the diamond roller cannot be sharp, and must be not less than 0.30 mm

[0121] cos aesg=d02 / Deg2=57.9679 / 71.195=0.814213;

[0122] aesg=Atn(Sqr(1-cos aesg^2) / cos aesg)=0.619424;

[0123] invaesg=Tan(aesg)-aesg=0.09361582;

[0124] Beg2=Atn(Deg2*Tan(Bf2) / Df2)=0.6448177;

[0125] Seng2=(sfn2 / cos(Bf2) / Df2+invaft2-invaesg)*Deg2*cos(Beg2)=0.3175>0.30.

[0126] The checking result shows that the addendum of the diamond roller is not sharp, and the parameter design reliability of the diamond roller is improved.

[0127] According to the new parameters of the inner honing roller, the calculation is performed according to the above steps, and the following results are obtainedFig. 3 The design parameters of the full-life diamond roller are obtained by intersecting the two groups of results:

[0128] For example, the dedendum diameter Deg2 of the diamond roller is 71.089 and 71.195 respectively in two results, the larger value is taken and the last digit is retained, Deg2 = 71.2;

[0129] The dedendum diameter Dig2 of the diamond roller is 54.797 and 54.015 respectively in two results, the smaller value is taken and the last digit is retained, Dig2 = 54;

[0130] The effective starting circle diameter dyx2 of the diamond roller is 57.9706 and 57.969 respectively in two results (see Fig. 3 the starting circle dNf of the middle roller), the smaller value is taken, dyx2 = 57.969;

[0131] The effective ending circle diameter dyz2 of the diamond roller is 69.4872 and 69.9086 respectively in two results, the larger value is taken, dyz2 = 69.9086;

[0132] The design parameters of the full-life diamond roller are as follows: Mn = 2.4552, Afn = 16.5°, Bf2 = 33°, Z2 = 21, Xn2 = 0.38, Deg2 = 71.2, Dig2 = 54, dyx2 = 57.969, dyz2 = 69.9086.

[0133] Before the implementation of the present application, it takes dozens of hours to design the diamond roller according to experience, but now it only takes twenty minutes to design the diamond roller, and the efficiency is at least increased by more than ten times. The present technology has been applied to the mass production process of high-speed gears of new energy reducers, and can be widely applied in the same industry.

[0134] After a long period of research and development, the applicant successfully developed the diamond roller design method for processing inner honing rollers, and the diamond roller designed and manufactured according to the method can complete the trimming of the inner honing roller at one time, improves the trimming efficiency and trimming accuracy of the inner honing roller, and creates a new efficient solution for batch processing of such high-speed gear products.

[0135] The above only describes the preferred embodiments of the present application and should not be used to limit the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application should be included in the protection scope of the present application.

Claims

1. A design method of full-life diamond roller for a powerful internal honing wheel, characterized by, The diamond roller is engaged with the inner gear of the inner honing wheel, and the design method comprises the following steps: According to the parameters of the external gear and the inner honing wheel, the design parameters of the diamond roller are determined; the design parameters of the diamond roller include normal modulus Mn, circular normal pressure angle Afn, helix angle Bf2, tooth number Z2, displacement coefficient Xn2, addendum circle diameter Deg2, dedendum circle diameter Dig2 and effective starting circle diameter dyx2; According to the effective involute termination point diameter of the inner honing wheel, the addendum circle diameter of the diamond roller is calculated, and the addendum width of the diamond roller is checked to ensure that the addendum is not sharp. According to the parameters of the new inner honing wheel and the old inner honing wheel, the design parameters of the two groups of diamond rollers are determined respectively, the intersection of the design parameters of the two groups of diamond rollers is taken, and the design parameters of the diamond roller with full life are obtained.

2. The design method of full life diamond roller for power internal honing wheel according to claim 1, characterized in that, According to the parameters of the external gear and the inner honing wheel, the design parameters of the diamond roller are determined; the design parameters of the diamond roller include normal modulus Mn, circular normal pressure angle Afn, helix angle Bf2, tooth number Z2, displacement coefficient Xn2, addendum circle diameter Deg2, dedendum circle diameter Dig2 and effective starting circle diameter dyx2; The normal modulus Mn, the helix angle Bf2 and the circular normal pressure angle Afn of the diamond roller are the same as those of the inner honing wheel; According to the displacement coefficient Xn of the external gear honed by the inner honing wheel and the tooth number Z1 of the inner honing wheel, the displacement coefficient Xn2 and the tooth number Z2 of the diamond roller are determined respectively; The normal pitch circle engagement angle ajn of the diamond roller and the inner honing wheel is calculated: The initial normal pitch circle engagement angle ajn=Afn+v, v is the angle conversion coefficient, v is π / 180; The iteration function fajn of the normal pitch circle engagement angle ajn is established, and the iteration of the normal pitch circle engagement angle ajn is performed: when the value of the iteration function is less than the set threshold, the end face engagement angle ajt11 and ajt21 are calculated according to the current value of the normal pitch circle engagement angle ajn.

3. The design method of full life diamond roller for power internal honing wheel according to claim 2, characterized in that, According to the parameters of the external gear and the inner honing wheel, the design parameters of the diamond roller are determined; the design parameters of the diamond roller include normal modulus Mn, circular normal pressure angle Afn, helix angle Bf2, tooth number Z2, displacement coefficient Xn2, addendum circle diameter Deg2, dedendum circle diameter Dig2 and effective starting circle diameter dyx2; According to the small diameter De1, the pitch circle diameter Dj1 and the large diameter expansion coefficient Cn1 of the inner honing wheel in the gap-free engagement, the addendum circle Deg2 of the diamond roller is calculated; According to the large diameter Di1, the pitch circle diameter Dj1 and the small diameter expansion coefficient Cn2 of the inner honing wheel in the gap-free engagement, the dedendum circle diameter Dig2 of the diamond roller is calculated; According to the actual engagement line length ga, the large diameter Di1, the base circle diameter d01 and the base circle helix angle B01 of the inner honing wheel, and the base circle helix angle B02 and the base circle diameter d02 of the diamond roller, the effective termination circle diameter dyx2 of the diamond roller is calculated.

4. The full-life diamond roller design method for a power internal honing wheel according to claim 3, characterized by, The addendum width Seng2 of the diamond roller is calculated, and it is determined that the addendum of the diamond roller is not sharp when the addendum width Seng2 of the diamond roller is greater than or equal to 0.30mm.

5. The method of designing a full-life diamond roller for a power internal honing wheel as recited in claim 4, wherein, The addendum width Seng2 of the diamond roller is calculated, and it is determined that the addendum of the diamond roller is not sharp when the addendum width Seng2 of the diamond roller is greater than or equal to 0.30mm.

6. The full-life diamond roller design method for a power internal honing wheel according to claim 5, wherein The addendum width Seng2 of the diamond roller is calculated, and it is determined that the addendum of the diamond roller is not sharp when the addendum width Seng2 of the diamond roller is greater than or equal to 0.30mm. Further comprising: According to the actual length of the engagement line ga, the base circle helix angle B01 of the inner honing wheel and the base circle diameter d01, and the addendum circle diameter Deg2, the base circle diameter d02 and the base circle helix angle B02 of the diamond roller, the addendum circle diameter Deg2 of the diamond roller and the effective involute termination point diameter dyz11 of the inner honing wheel are calculated.

7. The method of designing a full-life diamond roller for a power internal honing wheel as recited in claim 6, wherein Also included are: According to the actual length of the engagement line ga, the effective termination circle diameter dyz1, the base circle diameter d01 and the base circle helix angle B01 of the inner honing wheel, and the base circle diameter d02 and the base circle helix angle B02 of the diamond roller, the effective termination circle diameter dyz2 of the diamond roller is calculated.

8. The full-life diamond roller design method for a power internal honing wheel according to claim 7, characterized by, Also included are: According to the pitch circle diameter Dj1 of the inner honing wheel and the pitch circle diameter Dj2 of the diamond roller, the center distance A12 when the diamond roller and the inner honing wheel are engaged without clearance is calculated.

9. The method of designing a full-life diamond roller for a power internal honing wheel as recited in claim 8, wherein, Also included are: According to the base circle helix angle B01 and the circular end face pressure angle Aft1 of the inner honing wheel, and the base circle helix angle B02 and the circular end face pressure angle Aft2 of the diamond roller, the shaft intersection angle ∑ when the diamond roller and the inner honing wheel are engaged without clearance is calculated.

10. The method of designing a full-life diamond roller for a power internal honing wheel as recited in claim 9, wherein, Also included are: According to the circular normal pressure angle Afn, the normal pitch circle engagement angle ajn, the normal circular arc tooth thickness sfn2, the normal modulus Mn, the number of teeth Z2, the circular end face pressure angle Aft2 and the pitch circle end face engagement angle ajt21 of the diamond roller, the pitch circle tooth thickness sjn2 of the diamond roller is calculated.

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