Method and system for rapidly generating gear hobbing process package

Abstract

The invention relates to the technical field of process package generation, in particular to a gear hobbing process package rapid generation method and system, and the method comprises the steps: receiving gear basic parameters inputted by a user; verifying the validity of the basic parameters of the gear; the hob type is matched based on the verified parameters, and the hob diameter is calculated through a piecewise linear formula; the cutting speed range of the material is obtained based on the verified parameters, and core process parameters are calculated in combination with the cutting speed range, the verified parameters, the hob type and the hob diameter; on the basis of the gear basic parameters and the core process parameters, a machining program code is generated according to a preset rule, and a gear hobbing program is obtained; and the core process parameters and the gear hobbing program are displayed on a user interface in a centralized mode, and a numerical control machining program capable of being copied is generated. According to the method, the process design period can be greatly shortened, the machining efficiency is remarkably improved, and parameter consistency and program accuracy are guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of intelligent manufacturing technology of gear hobbing, covering gear meshing theory, material database, process knowledge base and numerical control programming, and specifically relates to a method and system for rapidly generating a gear hobbing process package. BACKGROUND

[0002] Gear is the core component of mechanical transmission, and its processing quality directly determines the transmission accuracy, noise level and service life of the equipment. In the current gear manufacturing industry, the design of the hobbing process has long been plagued by technical bottlenecks such as experience-based design, fragmented process, and low efficiency, which has become a key pain point restricting the industry's quality and efficiency. In terms of process design efficiency, traditional processes require experienced engineers to complete multiple rounds of manual operations. First, according to GB / T 1357-2008 standard, the geometric parameters such as the pitch circle diameter and the addendum circle diameter are calculated through the "Gear Handbook", which takes about 1 hour. Then, combined with the material hardness, the cutting speed is selected, and the feed rate is adjusted by referring to the tool sample, which needs to be calculated repeatedly for 3 to 5 times to balance the efficiency and tool life, which takes 2 to 3 hours. Finally, the numerical control G code is written based on experience, including rough machining layering, finishing and other logic, which takes very short time, can significantly improve the design efficiency, reduce the cost of production and improve the efficiency. In terms of process design efficiency, traditional processes require experienced engineers to complete multiple rounds of manual operations. First, according to GB / T 1357-2008 standard, the geometric parameters such as the pitch circle diameter and the addendum circle diameter are calculated through the "Gear Handbook", which takes about 1 hour. Then, combined with the material hardness, the cutting speed is selected, and the feed rate is adjusted by referring to the tool sample, which needs to be calculated repeatedly for 3 to 5 times to balance the efficiency and tool life, which takes 2 to 3 hours. Finally, the numerical control G code is written based on the tool and workpiece parameters and the machining parameter requirements, including rough machining layering, finishing and other logic, which takes very short time, can significantly improve the design efficiency, reduce the cost of production and improve the efficiency.

[0003] In the prior art, related auxiliary tools have obvious limitations. UG, Mastercam and other numerical control programming software need to manually input all machining parameters, lack parameter automatic calculation capability, and have high requirements for hardware configuration and complex operation. Single-function calculators can only complete isolated parameter calculation and cannot integrate material, tool and gear parameters to form a complete process package. Some open-source tools do not follow industry standards, and the generated G code needs to be modified twice to adapt to domestic numerical control equipment. In addition, existing tools are developed using compiled languages such as C++, which makes secondary development difficult and unable to flexibly adjust algorithm parameters according to actual processing data of enterprises. In view of the above problems, the industry urgently needs a modular, standardized and lightweight hobbing process generation scheme that can directly calculate tool parameters, material data, machining parameters and machining programs, and realize full-process automation from parameter input to program output. SUMMARY

[0004] Based on the aforementioned technical problems of traditional gear hobbing process design, which relies on manual experience, suffers from fragmented processes, low efficiency, and lacks parameter calculation capabilities, low system integration, insufficient standardization, and difficulties in secondary development, this invention provides a method and system for rapidly generating gear hobbing process packages. This invention primarily utilizes a dual parameter verification mechanism, a built-in dual database of materials and tools, a modular automatic process parameter calculation algorithm, and CNC program automatic generation logic that conforms to national standards. This significantly improves process design efficiency and consistency, reduces reliance on manual experience, ensures standardized machining parameters, and enables rapid deployment and flexible adaptation through a lightweight architecture.

[0005] The technical means employed in this invention are as follows: A method for rapidly generating a gear hobbing process package includes the following steps: Receives gear basic parameters input by the user, including module, number of teeth, tooth width, material, pressure angle, and helix angle; The validity of the gear basic parameters is verified, and the verified parameters are generated after the verification is passed. A tool database is constructed, and the hob type is matched based on the module in the verified parameters. The hob diameter is calculated using a piecewise linear formula. A material database is constructed, and the cutting speed range of the materials is obtained based on the verified parameters. The core process parameters are calculated by combining the cutting speed range, the verified parameters, the hob type and the hob diameter. The core process parameters include cutting speed, spindle speed, feed per revolution, feed rate, total depth of cut, roughing depth, finishing depth, speed ratio, tilt angle, machining time and cutting fluid type. Based on the gear basic parameters and core process parameters, a machining program code is generated according to preset rules to obtain a gear hobbing machining program. The preset rules include program number naming, initialization instruction set, roughing layer cutting logic, finishing parameter adjustment and program termination instructions. The core process parameters and the gear hobbing program are centrally displayed on the user interface, and a replicable CNC machining program is generated.

[0006] Furthermore, if the front-end verification fails, an error message is displayed on the front-end; if the front-end verification passes, the verified parameters are sent to the back-end; if the back-end verification fails, a structured error message is generated; if the back-end verification passes, the verified parameters are generated. The front-end verification includes parameter format and range validation, and the back-end verification includes validation of the integrity of required fields, data type conversion validation, and compliance of parameter ranges through Python function execution.

[0007] Furthermore, the specific rules for verifying whether the parameter range is compliant are as follows: The module ranges from 0.5 to 20 mm with a verification step of 0.1; the number of teeth ranges from 5 to 200 with a verification step of 1; the tooth width ranges from 5 to 500 mm with a verification step of 1; the pressure angle ranges from 14.5 to 30 degrees with a verification step of 0.5; and the helix angle ranges from -45 to 45 degrees with a verification step of 1. When any parameter exceeds its valid range, the backend generates a structured error message stating "the parameter name must be between the minimum and maximum values".

[0008] Furthermore, the calculation of the hob diameter based on the verified module-matched hob type using a piecewise linear formula includes: When the modulus in the verified parameters is less than or equal to 8, a high-speed steel hob is matched; when the modulus in the verified parameters is greater than 8, a carbide hob is matched. When the modulus in the verified parameters is not greater than 5, the hob diameter = 80 + 10 × modulus; when the modulus in the verified parameters is greater than 5, the hob diameter = 120 + 8 × (modulus - 5).

[0009] Furthermore, the method for calculating the cutting speed includes: The maximum and minimum cutting speeds are extracted based on the cutting speed range. When the modulus of the verified parameters is less than 2, the cutting speed is 0.9 times the maximum cutting speed. When the modulus in the verified parameters is greater than or equal to 2 and less than 5, the cutting speed is the average of the maximum cutting speed and the minimum cutting speed; When the modulus in the verified parameters is greater than 5, the cutting speed is 1.1 times the minimum cutting speed.

[0010] Furthermore, the formula for calculating the spindle speed is: spindle speed = (1000 × cutting speed) / (3.14159 × hob diameter), and rounded to the nearest integer multiple of 50 revolutions per minute; The calculation rule for the feed per revolution is as follows: when the material type is 45 steel or 40 chromium, the feed per revolution = 0.2 + 0.03 × module; for other materials, the feed per revolution = 0.15 + 0.025 × module. The formula for calculating the feed rate is: Feed rate = feed per revolution × spindle speed, rounded to the nearest integer multiple of 10 mm / min; The formula for calculating the total cutting depth is: Total cutting depth = 2.25 × module; The formula for calculating the roughing depth is: Roughing depth = Total cutting depth × 0.85; The formula for calculating the finishing depth is: Finishing depth = Total cutting depth × 0.15; The formula for calculating the processing time is: Processing time = (tooth width + 10) / feed rate; The matching rules for the cutting fluid type are as follows: when the material type is 45 steel, 20Cr manganese titanium or 40Cr, emulsion is matched; when the material type is HT300 or stainless steel 304, extreme pressure cutting oil is matched.

[0011] Furthermore, the preset rules of the gear hobbing process specifically include: Initialization commands include millimeter units, XY plane, tool compensation cancellation, fixed cycle cancellation, and absolute programming; The roughing stage is divided into three layers of cutting on average, with each cutting depth being one-third of the roughing depth; The feed rate during the finishing stage is set to 0.8 times the feed rate. The closing instructions include safely returning to the tool change point, turning off the coolant, and resetting the program to end.

[0012] Furthermore, the material database is a Python dictionary structure, containing at least the following five categories of steel parameters: 45 steel: hardness HB180-230, good machinability, cutting speed range 100 to 150 m / min; 20CrMnTi: Hardness HB170-210, machinability is average, cutting speed range is 80 to 120 m / min; 40Cr: Hardness HB200-250, moderate machinability, cutting speed range 90 to 140 m / min; HT300: Hardness HB180-240, poor machinability, cutting speed range 60 to 100 m / min; Stainless steel 304: Hardness HB150-180, poor machinability, cutting speed range 50 to 80 m / min; The tool database is also a Python dictionary structure, which is statically built-in during system runtime and cannot be dynamically modified.

[0013] Furthermore, the exception handling mechanism is as follows: Parameter calculation errors are handled through an exception handling mechanism, and the returned format is: parameter calculation error: error information with specific reason; The handler generates an exception and returns an error message in the format of "Program Generation Error: Specific Reason". When the front-end detects a communication error, it should notify the user via a pop-up window that the communication with the back-end has failed.

[0014] The present invention also includes a rapid generation system for gear hobbing process packages, used to implement the above-mentioned rapid generation method for gear hobbing process packages, comprising: The parameter input and verification module is used to receive the basic gear parameters input by the user, and to perform front-end pre-verification and back-end verification on the parameters to generate verified parameters. The hob parameter generation module is used to query the built-in tool database to match the hob type based on the module in the verified parameters, and calculate the hob diameter using a piecewise linear formula. The machining parameter generation module is used to query the built-in material database to obtain the cutting speed range based on the material type in the verified parameters, and to calculate the core process parameters, including cutting speed, spindle speed, feed rate, depth of cut, machining time and cutting fluid type, in combination with the verified parameters, hob type and hob diameter. The CNC machining program code generation module is used to generate hobbing program code based on the gear basic parameters and core process parameters, according to a preset hobbing program.

[0015] Compared with the prior art, the present invention has the following advantages: 1. This invention adopts a dual verification mechanism, which combines real-time front-end verification with deep back-end verification to effectively ensure the accuracy of input parameters and fundamentally solve the problem of process failure caused by human input errors.

[0016] 2. This invention constructs an integrated dual database of materials and cutting tools, systematically consolidating scattered process parameters. This avoids the tedious process of repeatedly consulting technical manuals in traditional machining, significantly improving the standardization of process design. Based on data verification, it possesses significant technical advantages, resulting in a substantial increase in efficiency. The process design cycle is shortened from 4 to 8 hours per piece to less than 3 minutes, improving efficiency by over 95%, and adapting to the needs of multi-variety, small-batch production.

[0017] 3. This invention adopts a modular algorithm architecture, which decouples the functions of parameter calculation and program generation, not only improving the maintainability of the system, but also providing a flexible technical foundation for subsequent functional expansion.

[0018] 4. The present invention adopts a lightweight system architecture, which greatly reduces deployment costs and hardware requirements, making it particularly suitable for the existing equipment conditions and technical levels of small and medium-sized manufacturing enterprises.

[0019] 5. This invention has a low operating threshold; even inexperienced personnel can operate it independently after one hour of training, reducing the company's talent training costs.

[0020] Based on the above reasons, this invention can be widely applied in fields such as process package generation. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a flowchart illustrating a method for rapidly generating a gear hobbing process package according to the present invention.

[0023] Figure 2 This is a diagram of the operation interface and parameter output interface of the rapid process generator for gear hobbing in this embodiment of the invention.

[0024] Figure 3 This is a schematic diagram of the parameter input and verification module in an embodiment of the present invention.

[0025] Figure 4 This is a schematic diagram of the architecture of the rapid generation system for gear hobbing process packages of the present invention. Detailed Implementation

[0026] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0027] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification and claims of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such processes, methods, products, or devices.

[0028] The technical solution of this invention covers mechanical manufacturing technology, computer application technology and CNC technology. It is applicable to hobbing of cylindrical gears and helical gears with a module of 0.5 to 20 mm and a number of teeth of 5 to 200. It can be widely used in manufacturing fields that rely on gear transmission, such as automotive transmissions, wind power equipment, and general machine tools. It is especially suitable for customized production needs of multiple varieties and small and medium batches.

[0029] The system in this invention is based on a lightweight design concept and is packaged into an independent executable file using PyInstaller. It does not rely on external databases or heavy software environments and can be quickly deployed in the process design stage of small and medium-sized manufacturing enterprises, providing a practical technical tool for the digital transformation of the traditional machining industry.

[0030] like Figure 1 As shown, this invention provides a method for rapidly generating a gear hobbing process package, the steps of which are as follows: S1. Receive the gear basic parameters input by the user. The gear basic parameters include module, number of teeth, tooth width, material, pressure angle and helix angle.

[0031] The above parameter set strictly corresponds to the list of required parameters in the parameter processing function in the source code, covering the core elements of gear geometry, material properties and machining parameters, providing complete input for subsequent calculations.

[0032] The system was developed using Python 3.9, with the front-end interface built on HTML5 and Tailwind CSS. Communication between the front-end and back-end is achieved through the WebView 4.2.2 library. The system was packaged using PyInstaller 5.6 to generate a standalone executable file. The development environment consisted of Windows 10 64-bit Professional Edition, an Intel i5-12400KF processor, 16GB DDR4 memory, a 256GB SSD, Microsoft .NET Framework 4.8, and WebView2 version 112.0.1722.68.

[0033] The system startup and initialization process is as follows: After double-clicking the exe file, the system first executes the function exposure logic and waits for the WebView2 component to finish loading. Once the component loads successfully, a 1200×800 pixel WebView window is created, titled "Gear Machining Process Package Generator," supporting minimize, maximize, and close operations, with a minimum size limit of 800×600 pixels. Subsequently, the front-end HTML content is loaded, and interactive objects are injected via JavaScript to complete the communication binding between the front-end and back-end functions. After initialization, the front-end console outputs "Back-end functionality loaded."

[0034] After receiving the basic gear parameters, the system first checks if PyCharm and the WebView2 plugin are installed. If not, the plugins should be installed. After installing the plugins, the initialization process continues.

[0035] like Figure 2As shown, the front-end interface adopts a three-column responsive design, with the parameter input area on the left and the result display area on the right. The parameter input area contains 6 parameter controls and a "Generate Process Package" button. The default values ​​for the controls are: module 3.5, number of teeth 28, tooth width 80, material 45 steel, pressure angle 20, and helix angle 12.

[0036] After receiving the basic gear parameters input by the user through the web front-end interface, the system first performs front-end pre-validation and provides immediate prompts for empty values, non-numerical inputs, and out-of-range values.

[0037] S2. Verify the basic parameters of the gear from both the front and back ends. Once the verification is successful, generate the verified parameters.

[0038] Specifically, if front-end validation fails, an error message is displayed on the front-end. If front-end validation succeeds, the validated parameters are encapsulated into a JSON object and the back-end parameter processing function is called via the communication interface. If back-end validation fails, a structured error message is generated. If back-end validation succeeds, validated parameters are generated. Front-end validation includes parameter format and range verification, while back-end validation includes verification of required field integrity, data type conversion, and parameter range compliance via Python function execution.

[0039] The specific rules for verifying whether the parameter range is compliant are as follows: The module ranges from 0.5 to 20 mm with a verification step of 0.1; the number of teeth ranges from 5 to 200 with a verification step of 1; the tooth width ranges from 5 to 500 mm with a verification step of 1; the pressure angle ranges from 14.5 to 30 degrees with a verification step of 0.5; and the helix angle ranges from -45 to 45 degrees with a verification step of 1. When any parameter exceeds its valid range, the backend generates a structured error message stating "the parameter name must be between the minimum and maximum values".

[0040] The dual validity verification step for parameters is fundamental to ensuring process accuracy, and it consists of front-end pre-verification and back-end deep verification. The front-end can perform real-time verification, listen for error events in the parameter input box, and display prompts for empty values, non-numeric inputs, and out-of-range values, such as "Please enter a valid number of teeth (5-200)". This logic corresponds to the parameter verification function in the front-end source code.

[0041] The backend deep validation is performed by a parameter processing function written in Python. First, it iterates through the list of required parameters, checking for any missing parameters. If a parameter is missing, it returns the name of the missing parameter. Second, it performs data type conversion, converting the module and tooth width to floating-point numbers, and the number of teeth to integers. If the conversion fails, it returns a parameter format error and the specific reason. Finally, it performs range validation, filtering invalid values ​​against a preset range to ensure that the input parameters meet the actual processing requirements.

[0042] S3. Construct a tool database, match the hob type based on the module in the verified parameters, and calculate the hob diameter using a piecewise linear formula.

[0043] The tool database contains the maximum compatible module, helix angle range, and efficiency parameters for high-speed steel hobs and carbide hobs. Specifically, when the modulus in the verified parameters is less than or equal to 8, a high-speed steel hob is matched; when the modulus in the verified parameters is greater than 8, a carbide hob is matched.

[0044] When the modulus in the verified parameters is not greater than 5, the hob diameter = 80 + 10 × modulus; when the modulus in the verified parameters is greater than 5, the hob diameter = 120 + 8 × (modulus - 5).

[0045] This step is implemented based on the tool database and calculation logic in the source code. The tool database is a built-in Python dictionary that defines two types of hob parameters: high-speed steel hobs have a maximum adaptable module of 8, a helix angle range of -30 to 30 degrees, and moderate efficiency; carbide hobs have a maximum adaptable module of 12, a helix angle range of -45 to 45 degrees, and high efficiency.

[0046] The hob type matching uses a module threshold judgment logic. When the module is not greater than 8, a high-speed steel hob is matched; when the module is greater than 8, a carbide hob is matched. This rule comes from the core logic in the source code that determines the hob type through condition judgment.

[0047] The hob diameter is calculated using a piecewise linear formula, which is an industry-experienced formula derived from statistical source code test cases. When the module is not greater than 5, the hob diameter is equal to 80 plus 10 multiplied by the module. For example, when the module is 3.5, the diameter is equal to 80 plus 10 multiplied by 3.5, which equals 115.0 mm. When the module is greater than 5, the hob diameter is equal to 120 plus 8 multiplied by the difference between the module and 5. For example, when the module is 10, the diameter is equal to 120 plus 8 multiplied by 5, which equals 160.0 mm. The calculation result is rounded to one decimal place to accommodate the precision of tool selection.

[0048] S4. Construct a material database. Based on the verified parameters, obtain the cutting speed range of the material. Combine the cutting speed range, verified parameters, hob type and hob diameter to calculate the core process parameters. The core process parameters include cutting speed, spindle speed, feed per revolution, feed rate, total depth of cut, roughing depth, finishing depth, speed ratio, tilt angle, machining time and cutting fluid type.

[0049] The core process parameter calculation step is the heart of the algorithm, implemented by the process parameter calculation function. It requires integrating the material database, gear parameters, and hob parameters for multi-dimensional calculations. First, the material database is called to obtain material properties; this database is a built-in dictionary in the source code. In a preferred embodiment of this invention, the material database is a Python dictionary structure, containing at least the following five categories of steel parameters: 45 steel: hardness HB180-230, good machinability, cutting speed range 100 to 150 m / min; 20CrMnTi: hardness HB170-210, moderate machinability, cutting speed range 80 to 120 m / min; 40Cr: hardness HB200-250, moderate machinability, cutting speed range 90 to 140 m / min; HT300: hardness HB180-240, poor machinability, cutting speed range 60 to 100 m / min; 304 stainless steel: hardness HB150-180, poor machinability, cutting speed range 50 to 80 m / min; The tool database is also a Python dictionary structure, statically built-in during system operation and cannot be dynamically modified.

[0050] The method for calculating cutting speed is as follows: The maximum and minimum cutting speeds are extracted based on the cutting speed range. When the modulus in the verified parameters is less than 2, the cutting speed is 0.9 times the maximum cutting speed; when the modulus in the verified parameters is greater than or equal to 2 and less than 5, the cutting speed is the average of the maximum and minimum cutting speeds; when the modulus in the verified parameters is greater than 5, the cutting speed is 1.1 times the minimum cutting speed. The cutting speed calculation uses a composite logic of material range and modulus segmentation. For example, when the material is 45 steel and the modulus is 3.5, the cutting speed is the average of 100 and 150, which equals 125.0 meters per minute.

[0051] The formula for calculating spindle speed is: Spindle speed = (1000 × cutting speed) / (3.14159 × hob diameter), rounded to the nearest integer multiple of 50 rpm. This method is compatible with the speed settings of most CNC gear hobbing machines, and this rounding logic corresponds to the source code's method of first dividing the spindle speed by 50, rounding it down, and then multiplying it by 50.

[0052] The calculation rule for feed per revolution is as follows: when the material type is 45 steel or 40 chromium, feed per revolution = 0.2 + 0.03 × module; for other materials, feed per revolution = 0.15 + 0.025 × module. This distinction logic comes from the conditional statement in the source code.

[0053] The formula for calculating the feed rate is: Feed rate = feed per revolution × spindle speed, and rounded to the nearest integer multiple of 10 mm / min to simplify parameter adjustment.

[0054] The speed ratio is directly equal to the number of teeth, matching the indexing requirements of gear hobbing.

[0055] The tilt angle reuses the input helix angle to ensure accurate machining posture.

[0056] The formula for calculating the total depth of cut is: Total depth of cut = 2.25 × module.

[0057] The formula for calculating the roughing depth is: Roughing depth = Total cutting depth × 0.85.

[0058] The formula for calculating the finishing depth is: Finishing depth = Total cutting depth × 0.15, and this ratio is set as a fixed coefficient in the corresponding source code.

[0059] The formula for calculating machining time is: Machining time = (tooth width + 10) / feed rate; The matching rules for cutting fluid types are as follows: when the material type is 45 steel, 20CrMnTi or 40Cr, emulsion is matched; when the material type is HT300 or stainless steel 304, extreme pressure cutting oil is matched. This ratio is set to a fixed coefficient in the corresponding source code.

[0060] S5. Based on the gear's basic parameters and core process parameters, generate machining program code according to preset rules to obtain the gear hobbing machining program. The preset rules include program number naming, initialization instruction set, roughing layered cutting logic, finishing parameter adjustment, and program termination instructions.

[0061] The CNC program generation step is implemented by the CNC program generation function, strictly following the GB / T 8190 standard and source code logic.

[0062] The preset rules for gear hobbing are as follows: The naming rule for program numbers is: % 000 plus the number of teeth plus the result of multiplying the module by 10 and taking the integer part.

[0063] The program structure comprises seven core parts: program header, initialization instruction set, tool change and spindle start, rapid positioning, roughing instructions, finishing instructions, and program termination. The initialization instructions include millimeter settings, XY plane settings, tool compensation cancellation, fixed cycle cancellation, and absolute programming.

[0064] The roughing stage is divided into three layers of cutting, with each layer having a cutting depth of one-third of the roughing depth. Each depth is equal to the roughing depth divided by 3. The X-coordinate decreases with the depth, corresponding to the loop logic in the source code. This loop is executed three times, and each time the current cutting depth is calculated as the sum of the total roughing depth multiplied by the loop count plus 1, divided by 3. A G00 instruction containing the corresponding X and Z coordinates is added to the program.

[0065] The feed rate for the finishing stage is set to 0.8 times the feed rate, corresponding to the logic of setting the feed rate to 0.8 times the roughing feed rate and retaining one decimal place; the program termination includes returning to the safe position, turning off the cutting fluid, and resetting the program to ensure machining safety.

[0066] The closing instructions include safely returning to the tool change point, turning off the coolant, and resetting the program to end.

[0067] S6. Display the core process parameters and the gear hobbing program on the user interface and generate a CNC machining program that can be copied.

[0068] The backend returns the core process parameters and CNC program to the frontend. The frontend uses the process parameter display function to fill the parameters into the card grid, displaying the generated parameter names and values ​​as well as the copyable machining program. The CNC program is displayed in the tabs, supporting horizontal scrolling and syntax highlighting.

[0069] After the user clicks the copy button, the front end implements the copy through the clipboard writing function. This interaction logic corresponds to the copy button click event handling function in the source code front end, simplifying the process of importing the program into the device.

[0070] The method in this embodiment of the invention also includes an exception handling mechanism, which specifically includes: The exception handling mechanism handles parameter calculation exceptions and returns an error message in the format of "Parameter calculation error: specific reason". The mechanism also handles program-generated exceptions and returns an error message in the format of "Program generation error: specific reason". When the front-end captures a communication exception, a pop-up window is displayed to the user indicating that communication with the back-end has failed.

[0071] As a preferred embodiment of the present invention, after the user clicks the copy program button, the front end realizes the copy through the clipboard writing function. The actual test shows that the copy function supports the clipboard of Windows 10 and 11, and there is no formatting error when pasting to Notepad or CNC equipment program editor.

[0072] like Figure 4 As shown, the rapid generation system for gear hobbing process packages implemented in this invention includes the following modules for realizing the rapid generation method of gear hobbing process packages: The parameter input and verification module is used to receive the basic gear parameters input by the user, and to perform front-end pre-validation and back-end validation on the parameters to generate validated parameters.

[0073] The hob parameter generation module is used to query the built-in tool database to match the hob type based on the module in the verified parameters, and calculate the hob diameter using a piecewise linear formula.

[0074] The machining parameter generation module is used to query the built-in material database to obtain the cutting speed range based on the material type in the verified parameters, and to calculate the core process parameters, including cutting speed, spindle speed, feed rate, depth of cut, machining time and cutting fluid type, by combining the verified parameters, hob type and hob diameter.

[0075] The CNC machining program code generation module is used to generate hobbing program code based on the gear's basic parameters and core process parameters, according to a preset hobbing program.

[0076] In this system, the components interact via a bus, and the specific hardware configuration and functions are designed based on the requirements of the source code. The processor is an Intel i5 or higher clock speed processor, capable of tens of millions of floating-point operations per second, enabling rapid execution of parameter calculations and program generation logic. For large-scale parameter optimization scenarios, a GPU or TPU can be integrated to improve algorithm iteration efficiency. This configuration is adapted to the Python numerical computation requirements of the source code.

[0077] The interactive module consists of a display device and an input device, showcasing the three functional areas of the web front-end interface. The input device allows users to directly input data, which is then calculated and displayed on the front-end interface. The front-end interface supports dark mode switching to reduce visual fatigue during prolonged use.

[0078] The system software environment is designed based on the requirements of gear hobbing, and the operating system is Windows 10 64-bit or above; it depends on Microsoft .NET Framework 4.8 or above and Python 3.7 or above; the source code is packaged into a standalone exe file using PyInstaller, which can run without a Python environment, reducing the difficulty of deployment.

[0079] like Figure 3 As shown, the parameter input and verification module's process begins with the user inputting six basic gear parameters, including module and number of teeth. The system then parses the input data. First, it verifies the completeness of the parameters. If any item is missing, an error message indicating a missing necessary parameter is output. If all parameters are complete, the system proceeds to the parameter range compliance verification stage, checking each parameter against a preset valid range. If any parameter exceeds the specified range, an error message indicating that the parameter is out of range is output. Only parameters that pass both verifications are considered correct and passed to subsequent processing stages.

[0080] Example 1 This embodiment details the specific implementation process of parameter input and dual verification. When the user inputs parameters such as module 5, number of teeth 60, tooth width 100mm, material 40Cr, pressure angle 20°, and helix angle 15°, and clicks the "Generate Process Package" button, the system first performs front-end pre-verification: verifying that all parameters are not empty, are valid numbers, and are within the preset range. After the pre-verification passes, the front-end encapsulates the parameters into a JSON object and calls the back-end parameter processing function through the communication interface.

[0081] After receiving the parameters, the backend performs deep validation: confirming that the required parameters are complete, performing data type conversion (module, tooth width, etc., converted to floating-point, tooth count converted to integer), and verifying that all parameters are within the valid range. Once validation passes, the calculation phase begins.

[0082] During the hob parameter generation stage, the system automatically matches high-speed steel hobs based on the condition that the module is 5≤8. The hob diameter is calculated using a piecewise linear formula: since the module is 5>5, the diameter = 120 + 8 × (5-5) = 120.0 mm. The calculation result is displayed in real time on the front-end interface.

[0083] The core process parameter calculation process is as follows: The system calls the material database to obtain the cutting speed range of 40Cr from 90-140 m / min; based on the modulus 5 > 5, the cutting speed is taken as 110% of the lower limit of the range, i.e., 90 × 1.1 = 99.0 m / min; the spindle speed is calculated using the formula (1000 × 99) / (3.14159 × 120), and the result is rounded to 250 r / min (50 r / min); based on the characteristics of 40Cr material, the feed per revolution = 0.2 + 0.03 × 5 = 0.3 5mm / r; Feed rate = 0.35 × 250 = 87.5mm / min, rounded to 90mm / min (10mm / min is rounded up); Speed ​​ratio is directly taken as 60 teeth; Total depth of cut = 2.25 × 5 = 11.25mm; Roughing depth = 11.25 × 0.85 = 9.56mm; Finishing depth = 11.25 × 0.15 = 1.69mm; Machining time = (100 + 10) / 90 ≈ 1.22min; According to the material matching rules, the cutting fluid type is determined to be emulsion. The final system generates a process parameter dictionary containing 12 core parameters, completely consistent with the code output structure.

[0084] Example 2 This embodiment further demonstrates the system's computational capabilities and practical application effects under different parameters. When the input parameters are module 2, number of teeth 150, tooth width 50mm, material 304 stainless steel, pressure angle 25°, and helix angle -10°, the system processing flow is as follows: The cutting speed range of 50-80m / min is obtained by querying the material database; based on the determination that module 2 < 2, the cutting speed is taken as 90% of the upper limit of the range, i.e., 80 × 0.9 = 72.0m / min; hob diameter = 80 + 10 × 2 = 100.0mm; spindle speed = (1000 × 72) / (3.1415) 9×100), rounded to 250 r / min; feed per revolution = 0.15 + 0.025 × 2 = 0.20 mm / r; feed rate = 0.20 × 250 = 50 mm / min; total depth of cut = 2.25 × 2 = 4.5 mm; roughing depth = 4.5 × 0.85 = 3.83 mm; finishing depth = 4.5 × 0.15 = 0.68 mm; machining time = (50 + 10) / 50 = 1.2 min; cutting fluid type is extreme pressure cutting oil. All parameter settings meet the machining characteristics requirements of stainless steel materials.

[0085] In terms of CNC program generation, taking a module of 5 and a tooth count of 60 as an example: the program number is generated according to the rule %0006050; the initialization instruction set includes G21 (millimeters), G17 (XY plane), G40 (tool compensation cancellation), G80 (fixed cycle cancellation), and G90 (absolute programming); the tool change and spindle commands are T1 M6 and S250 M3; the rapid positioning command is G00 X100. Z50. A0. The roughing stage uses three-layer cutting, each with a depth of approximately 3.19mm, and the specific instruction sequence includes coordinate positioning and feed commands. In the finishing stage, the feed rate is adjusted to 80% of the roughing speed, i.e., 72.0mm / min. The program termination includes safety return, coolant shut-off, and program end commands. The generated 32 lines of program code fully comply with the GB / T 8190 standard and can be directly imported into the CNC machine tool for operation.

[0086] Results and interactive tests show that the front-end dynamically fills the 12 parameters into the card grid through the process parameter display function. The CNC program uses a fixed-width font displayed in a dedicated label area and supports horizontal scrolling. The exception handling mechanism has been fully verified: when an unknown material is input, it returns a parameter calculation error: the unknown material is not in the material database; when parameters are missing, it returns a program generation error: the number of teeth is missing in the parameters; when communication is abnormal, it prompts a call error: communication with the backend failed.

[0087] The simulated machining test used 40Cr gears and a system-generated process plan (high-speed steel hob, cutting speed 99 m / min, spindle speed 250 r / min, feed rate 90 mm / min, 3 roughing and 1 finishing operations). The actual machining quality of 100 gears was measured: tooth profile tolerance 0.012-0.018 mm, surface roughness Ra=1.6 μm, and a pass rate of 98.5%. Compared with the traditional manual method, the pass rate increased by 7.5%, the single-piece process design time was reduced from 3 hours to 2 minutes, and the production preparation cycle was shortened by 95%.

[0088] The system boasts excellent scalability: the material database can be expanded to support new materials such as titanium alloys and aluminum alloys; the tool database can add new types such as coated high-speed steel hobs and carbide coated hobs, requiring only the addition of corresponding entries without modifying the core calculation logic. Algorithm parameters are easily adjustable, with key coefficients defined as constants. Enterprises can optimize parameters based on historical machining data, such as adjusting the cutting speed coefficient for modules less than 2 to 0.95 to improve efficiency. After modification, repackaging allows for rapid deployment, demonstrating strong engineering adaptability.

[0089] In terms of economic benefits, this invention demonstrates significant advantages. Compared with traditional manual process design, it not only greatly reduces design costs but also improves processing efficiency and product qualification rate by optimizing processing parameters, while ensuring the consistency and repeatability of process parameters.

[0090] In terms of industry application value, the technical framework of this invention has good portability and can be directly applied to other gear processing procedures. Only the database parameters and calculation logic need to be adjusted according to specific process requirements. This provides a reusable technical solution for comprehensive automation in the field of machining processes.

[0091] In summary, this invention constructs a fully automated solution for generating gear hobbing processes, effectively solving the problems of low efficiency, poor consistency, and high barriers to entry in traditional process design. It possesses significant technological advancement, practicality, and economic benefits, and meets the development needs of the machinery manufacturing industry.

[0092] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. The scope of protection of the present invention is based on equivalent modifications or system component adaptations made based on the logic of the inventive code, all of which fall within the scope of protection of the present invention; any new functions that deviate from the built-in database and algorithm logic of the source code are not within the scope of protection of the present invention.

Claims

1. A method for rapidly generating a gear hobbing process package, characterized in that, Includes the following steps: Receives gear basic parameters input by the user, including module, number of teeth, tooth width, material, pressure angle, and helix angle; The validity of the gear basic parameters is verified, and the verified parameters are generated after the verification is passed. A tool database is constructed, and the hob type is matched based on the module in the verified parameters. The hob diameter is calculated using a piecewise linear formula. A material database is constructed, and the cutting speed range of the materials is obtained based on the verified parameters. The core process parameters are calculated by combining the cutting speed range, the verified parameters, the hob type and the hob diameter. The core process parameters include cutting speed, spindle speed, feed per revolution, feed rate, total depth of cut, roughing depth, finishing depth, speed ratio, tilt angle, machining time and cutting fluid type. Based on the gear basic parameters and core process parameters, a machining program code is generated according to preset rules to obtain a gear hobbing machining program. The preset rules include program number naming, initialization instruction set, roughing layer cutting logic, finishing parameter adjustment and program termination instructions. The core process parameters and the gear hobbing program are centrally displayed on the user interface, and a replicable CNC machining program is generated.

2. The method according to claim 1, characterized in that, If the front-end validation fails, an error message is displayed on the front-end. If the front-end validation passes, the validated parameters are sent to the back-end. If the back-end validation fails, a structured error message is generated. If the back-end validation passes, validated parameters are generated. The front-end validation includes parameter format and range verification. The back-end validation includes verification of the integrity of required fields, data type conversion, and compliance of parameter ranges through Python function execution.

3. The method according to claim 2, characterized in that, The specific rules for verifying whether the parameter range is compliant are as follows: The module ranges from 0.5 to 20 mm with a verification step of 0.1; the number of teeth ranges from 5 to 200 with a verification step of 1; the tooth width ranges from 5 to 500 mm with a verification step of 1; the pressure angle ranges from 14.5 to 30 degrees with a verification step of 0.5; and the helix angle ranges from -45 to 45 degrees with a verification step of 1. When any parameter exceeds its valid range, the backend generates a structured error message: "The parameter name must be between the minimum and maximum values." 4. The method according to claim 1, characterized in that, The hob diameter is calculated using a piecewise linear formula based on the verified modulus-matched hob type, including: When the modulus in the verified parameters is less than or equal to 8, a high-speed steel hob is matched; when the modulus in the verified parameters is greater than 8, a carbide hob is matched. When the modulus in the verified parameters is not greater than 5, the hob diameter = 80 + 10 × modulus; when the modulus in the verified parameters is greater than 5, the hob diameter = 120 + 8 × (modulus - 5).

5. The method according to claim 1, characterized in that, The method for calculating the cutting speed includes: The maximum and minimum cutting speeds are extracted based on the cutting speed range. When the modulus in the verified parameters is less than 2, the cutting speed is 0.9 times the maximum cutting speed. When the modulus in the verified parameters is greater than or equal to 2 and less than 5, the cutting speed is the average of the maximum cutting speed and the minimum cutting speed; When the modulus in the verified parameters is greater than 5, the cutting speed is 1.1 times the minimum cutting speed.

6. The method according to claim 1, characterized in that, The formula for calculating the spindle speed is: Spindle speed = (1000 × cutting speed) / (3.14159 × hob diameter), and rounded to the nearest integer multiple of 50 revolutions per minute; The calculation rule for the feed per revolution is as follows: when the material type is 45 steel or 40 chromium, the feed per revolution = 0.2 + 0.03 × module; For other materials, the feed per revolution = 0.15 + 0.025 × module; The formula for calculating the feed rate is: Feed rate = feed per revolution × spindle speed, rounded to the nearest integer multiple of 10 mm / min; The formula for calculating the total cutting depth is: Total cutting depth = 2.25 × module; The formula for calculating the roughing depth is: Roughing depth = Total cutting depth × 0.85; The formula for calculating the finishing depth is: Finishing depth = Total cutting depth × 0.15; The formula for calculating the processing time is: Processing time = (tooth width + 10) / feed rate; The matching rules for the cutting fluid type are as follows: when the material type is 45 steel, 20Cr manganese titanium or 40Cr, emulsion is matched; when the material type is HT300 or stainless steel 304, extreme pressure cutting oil is matched.

7. The method according to claim 1, characterized in that, The preset rules of the gear hobbing process specifically include: Initialization commands include millimeter units, XY plane, tool compensation cancellation, fixed cycle cancellation, and absolute programming; The roughing stage is divided into three layers of cutting on average, with each cutting depth being one-third of the roughing depth; The feed rate during the finishing stage is set to 0.8 times the feed rate. The closing instructions include safely returning to the tool change point, turning off the coolant, and resetting the program to end.

8. The method according to claim 1, characterized in that, The material database is a Python dictionary structure and contains at least the following 5 categories of steel parameters: 45 steel: hardness HB180-230, good machinability, cutting speed range 100 to 150 m / min; 20CrMnTi: Hardness HB170-210, machinability is average, cutting speed range is 80 to 120 m / min; 40Cr: Hardness HB200-250, moderate machinability, cutting speed range 90 to 140 m / min; HT300: Hardness HB180-240, poor machinability, cutting speed range 60 to 100 m / min; Stainless steel 304: Hardness HB150-180, poor machinability, cutting speed range 50 to 80 m / min; The tool database is also a Python dictionary structure, which is statically built-in during system runtime and cannot be dynamically modified.

9. The method according to claim 1, characterized in that, The method further includes an exception handling mechanism, which is as follows: Parameter calculation errors are handled through an exception handling mechanism, and the returned format is: parameter calculation error: error information with specific reason; The handler generates an exception and returns an error message in the format of "Program Generation Error: Specific Reason". When the front-end detects a communication error, it should notify the user via a pop-up window that the communication with the back-end has failed.

10. A rapid generation system for gear hobbing process packages, characterized in that, A method for rapidly generating a gear hobbing process package according to any one of claims 1 to 9 includes: The parameter input and verification module is used to receive the basic gear parameters input by the user, and to perform front-end pre-verification and back-end verification on the parameters to generate verified parameters. The hob parameter generation module is used to query the built-in tool database to match the hob type based on the module in the verified parameters, and calculate the hob diameter using a piecewise linear formula. The machining parameter generation module is used to query the built-in material database to obtain the cutting speed range based on the material type in the verified parameters, and to calculate the core process parameters, including cutting speed, spindle speed, feed rate, depth of cut, machining time and cutting fluid type, in combination with the verified parameters, hob type and hob diameter. The CNC machining program code generation module is used to generate hobbing program code based on the gear basic parameters and core process parameters, according to a preset hobbing program.

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