A straight profile torus face worm turning machine tool and a turning method

Abstract

The application discloses a straight profile ring surface worm turning machining machine tool and a machining method, wherein the machine tool comprises a machine tool body, a driving assembly, a tool assembly and a control assembly; the driving assembly is arranged on the machine tool body; the tool assembly is arranged on the machine tool body and located on the side surface of the machine tool body, the tool assembly comprises a cutter head engaged with a worm blank, a plurality of turning groups are arranged on the cutter head, and the turning groups are fixed on the outer circumferential surface of the cutter head in the circumferential direction of the cutter head at equal intervals; and the control assembly is arranged on the machine tool body and electrically connected with the driving assembly and the tool assembly respectively. The machining method comprises connection and turning. The straight profile ring surface worm turning machining machine tool and the machining method are characterized in that a plurality of turning groups are arranged, the cutter head and the plurality of cutting tools form a worm gear type cutter similar to a worm gear, the cutter head is equivalent to a worm gear body, the cutting tools are equivalent to worm gear teeth, the worm gear type cutter is engaged with the worm blank to cut out worm teeth, and the machined worm is closer to a worm theoretical value.

Description

Technical Field

[0001] This invention belongs to the field of machine tool technology, specifically relating to a machine tool and machining method for machining straight-profile toroidal worm gears. Background Technology

[0002] Straight-profile toroidal worms, also known as TSL-type worms, have a load-bearing capacity four times that of ordinary cylindrical worms, but their machining process is complex and costly. Xie Peng, in *Economic and Technological Cooperation Information*, 2018, Issue 20, demonstrated the feasibility of using a gear hobbing machine and expanding its machining range, but the machining efficiency was low. Li Song, in *Industry and Technology Forum*, 2011, Issue 24, described machining toroidal worms using a macro program on a CNC lathe, where the helical surface is formed by the movement of the grooving tool tip, often resulting in insufficient surface roughness. China Agricultural University invented a turning method for the helical surface of the worm on a CNC lathe with a C-axis, which has high machining efficiency but also high machine tool costs. Common machining methods for toroidal worms include whirl milling, CNC turning, and multi-axis machine tool machining. These methods are variable parameter machining methods and can only produce straight-profile toroidal worms with unequal pitch helices. Summary of the Invention

[0003] The purpose of this invention is to provide a machine tool and method for machining straight-profile toroidal worm gears. This machining method utilizes the meshing motion of a toothed cutting tool and the worm blank to cut the worm tooth profile, resulting in a worm gear that more closely approximates the theoretical worm tooth shape.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] In a first aspect, the present invention provides a machine tool for machining straight-profile toroidal worm gears, comprising a machine tool body, a drive assembly, a tool assembly, and a control assembly;

[0006] The drive assembly is mounted on the machine tool body, and the machine tool body is provided with a tailstock located on the opposite side of the drive assembly. Between the drive assembly and the tailstock is a worm clamping part for clamping the worm blank.

[0007] The tool assembly is mounted on the machine tool body and located on the side of the machine tool body. The tool assembly includes a cutter head that meshes with the worm blank. The cutter head is provided with multiple turning groups. The turning groups are fixed at equal intervals along the circumference of the cutter head. Each turning group includes a bottom turning tool for machining the bottom surface of the worm tooth groove, a left-cutting turning tool for machining the left side surface of the worm, and a right-cutting turning tool for machining the right side surface of the worm. The bottom turning tool, the left-cutting turning tool, and the right-cutting turning tool are fixed at equal intervals along the circumference of the cutter head.

[0008] The control components are mounted on the machine tool body and electrically connected to the drive components and tool components respectively, so as to form a constant transmission ratio and achieve the optimal cutting speed.

[0009] In one possible design, the drive assembly includes a spindle motor and a spindle, with the output of the spindle motor connected to the spindle via a first reducer, and the spindle rotationally mounted on the machine tool body.

[0010] The tailstock is slidably mounted on the machine tool body and located on the opposite side of the spindle. The gap between the tailstock and the spindle is the worm gear clamping part. The spindle is provided with a chuck for clamping the worm gear blank, and the tailstock is provided with a center for abutting the worm gear blank.

[0011] In one possible design, the tool assembly includes a tool assembly body located on the machine tool body, a dial handle rotatably mounted on the tool assembly body, and a motor fixedly connected to the tool assembly body. The tool assembly body is connected to the machine tool body via a dovetail guide rail. The dial handle and the motor are located at opposite ends of the tool assembly body. The output end of the dial handle is connected to the dovetail guide rail, and the output end of the motor is connected to the tool disc via a second reducer.

[0012] In one possible design, the control components include a frequency converter module and a fine-tuning module. The frequency converter module includes a first frequency converter electrically connected to the drive assembly and a second frequency converter electrically connected to the tool assembly. The fine-tuning module includes a first fine-tuner electrically connected to the first frequency converter, a second fine-tuner electrically connected to the second frequency converter, and a master fine-tuner electrically connected to both the first and second frequency converters.

[0013] In one possible design, the cutter head includes an upper cutter head and a lower cutter head, wherein the upper cutter head has an upper cutter head shaft hole in the middle, the lower cutter head has a lower cutter head shaft hole in the middle, and a number of tool fixing grooves evenly distributed in the circumferential direction of the lower cutter head are provided on the outer side of the lower cutter head shaft hole.

[0014] When the upper cutter head is connected to the lower cutter head by the first bolt, the shaft holes of the upper cutter head and the lower cutter head are coaxial and connected to form a transmission hole. A rotating shaft is installed through the transmission hole. The end of the rotating shaft is connected to the upper cutter head through a pressure plate, and the rotating shaft is connected to the lower cutter head through a flat key.

[0015] In one possible design, a tool is detachably mounted in the tool retaining groove. The tool includes a tool body, a tool core, a tool head, and a blade. The tool core is inserted into the tool body and extends to the outside of one end of the tool body, where a scale is provided.

[0016] The cutter head includes a column adapted to the dial and a base for placing the blade. One side of the column is provided with a slot adapted to the blade core, and the other side of the column is connected to the base. The column is also provided with a connecting groove located on the side of the base. A second bolt is detachably provided on the connecting groove. Correspondingly, the dial is provided with a connecting hole adapted to the second bolt.

[0017] The top surface of the base is adapted to the placement surface of the blade. The blade is connected to the base by a third bolt. The blade is equipped with a pressure block, which is connected to the base by a fourth bolt.

[0018] The insert has multiple working surfaces, one of which has a cutting edge to form the bottom groove tool, left-hand cutting tool, or right-hand cutting tool, respectively.

[0019] In one possible design, the first bolt is located between adjacent tool fixing slots, and the upper tool disc is also provided with secondary bolts for connecting the tools, with each tool connected to two secondary bolts.

[0020] In one possible design, the connecting groove is constructed as an arc-shaped groove so that the cutter head can rotate relative to the cutter body with the cutter core as the center. The maximum range of rotation is the arc length of the arc-shaped groove, and the outer periphery of the dial is provided with a scale for displaying the angle.

[0021] The dial has teeth on its side for the first end face, and correspondingly, the column has teeth on its side for the second end face that are adapted to the teeth on the first end face.

[0022] In one possible design, when forming the left-hand or right-hand cutting tool, the insert has an asymmetrical triangular structure, the cutting edge is located on the side of the asymmetrical triangular structure, and the rake angle of the cutting edge is 24°-25° and the clearance angle of the cutting edge is 4°-6°.

[0023] When forming the groove bottom turning tool, the insert has a rectangular structure, and the cutting edge is located on the front end face of the rectangular structure.

[0024] Secondly, the present invention provides a method for machining a straight-profile toroidal worm gear, comprising the following steps:

[0025] Connection: The worm blank is clamped in a straight-profile toroidal worm turning machine tool;

[0026] Turning: Start the straight profile toroidal worm turning machine tool to process the worm blank into a worm;

[0027] The step-turning process includes the following movements:

[0028] Main motion: The worm blank is rotated by the drive assembly;

[0029] Generating motion: The cutter head rotates and meshes with the worm blank. For every 1 revolution of the worm blank, the cutter head rotates K / Z revolutions, where K is the number of worm threads and Z is the number of cutters on the cutter head.

[0030] Feed motion: Driven by the tool assembly, the cutter head makes a vertical feed motion along the radial direction of the worm blank to cut out the full tooth width of the worm;

[0031] Step-turning includes the following steps:

[0032] Start the drive assembly and the tool assembly. The drive assembly drives the worm blank to rotate, and the tool assembly drives the cutter head to rotate.

[0033] The control components are used to make the cutter head and worm gear blank rotate relative to each other according to a fixed transmission ratio;

[0034] The bottom cutting tool, the left cutting tool, and the right cutting tool are used to turn the bottom surface of the worm tooth groove, the left side surface of the worm, and the right side surface of the worm in sequence.

[0035] The tool assembly drives the tool head to perform lateral feed.

[0036] Beneficial effects:

[0037] By setting up multiple turning groups, the cutter head and multiple cutting tools form a worm gear tooth profile tool similar to a worm wheel. The cutter head is equivalent to the worm wheel body, and the cutting tools are equivalent to the worm wheel teeth. The worm tooth profile is cut out by the meshing motion between the worm gear tooth profile tool and the worm blank, and the machined worm is closer to the theoretical value of the worm.

[0038] The turning assembly includes a bottom-cutting tool, a left-hand cutting tool, and a right-hand cutting tool. These three tools machine the worm gear teeth sequentially from different directions, preventing the worm gear teeth from being machined by all three tools simultaneously. This reduces the cutting force per tooth and avoids tool breakage. The bottom-cutting tool shapes the basic form of the worm, while the left-hand and right-hand cutting tools have straight cutting edges, resulting in non-developable ruled surfaces on the worm gear teeth, which are closer to the theoretical values.

[0039] Meanwhile, by setting up multiple cutting groups, the number of times the worm gear blank is cut during one revolution of the cutter head is increased, which greatly improves the machining efficiency; and each cutting tool only has one edge participating in the cutting, which helps to reduce the cutting force, improve machining accuracy and tool life.

[0040] When both the left-hand and right-hand cutting tools are cutting simultaneously during the machining process, the component forces along the worm gear axis are in opposite directions. This can eliminate the impact of mechanical transmission backlash on the accuracy of the tool head movement and improve machining accuracy.

[0041] The cutting head in the tool can rotate relative to the tool body. The tool angle can be changed according to the worm module and lead, which can adapt to the machining of worms with various modules, thus improving the range of applications and increasing practicality. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of a machine tool for machining straight-profile toroidal worm gears.

[0043] Figure 2 This is a schematic diagram of the drive component.

[0044] Figure 3 This is a schematic diagram of the tool assembly.

[0045] Figure 4 This is a schematic diagram of the control component.

[0046] Figure 5 This is a schematic diagram of the cutting principle.

[0047] Figure 6 This is a schematic diagram of the cutting surfaces of the bottom-cutting tool, the left-cutting tool, and the right-cutting tool.

[0048] Figure 7 This is a schematic diagram of the cutter head and its AA section.

[0049] Figure 8 This is a schematic diagram of the upper cutter head and its AA section.

[0050] Figure 9 This is a schematic diagram of the lower cutter head and its AA section.

[0051] Figure 10 This is a schematic diagram of the tool structure when the insert is a left-hand cutting tool.

[0052] Figure 11 This is a cross-sectional view of a cutting tool with a left-hand cutting edge.

[0053] Figure 12 This is a top view of the cutting tool when the insert is a left-hand cutting tool.

[0054] Figure 13 The three views of the cutting tool when the insert is a right-hand cutting tool.

[0055] Figure 14 The three views of the cutting tool when the insert is constructed as a bottom-grooving turning tool.

[0056] In the picture:

[0057] 100. Machine tool body; 101. Tailstock; 102. Center; 200. Drive assembly; 201. Spindle motor; 202. Spindle; 203. First reducer; 204. Chuck; 300. Tool assembly; 31. Tool head; 311. Upper tool head; 312. Lower tool head; 301. Upper tool head shaft hole; 302. Lower tool head shaft hole; 303. Tool fixing slot; 304. First bolt; 305. Pressure plate; 306. Flat key; 307. Secondary bolt; 32. Tool assembly body; 33. Dial handle; 34. Motor; 35. Second reducer; 351. Rotary shaft; 400. Control assembly ; 410, Variable frequency module; 411, First variable frequency drive; 412, Second variable frequency drive; 420, Fine-tuning module; 421, First fine-tuner; 422, Second fine-tuner; 423, Main fine-tuner; 500, Cutting tool; 51, Bottom slot cutting tool; 52, Left-edge cutting tool; 53, Right-edge cutting tool; 501, Tool body; 502, Tool core; 503, Tool head; 503a, Column; 503b, Support; 504, Insert; 505, Dial; 506, Connecting groove; 507, Second bolt; 508, Third bolt; 509, Pressure block; 510, Fourth bolt; 511, Cutting edge; 512, Scale. Detailed Implementation

[0058] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the present invention will be briefly introduced below in conjunction with the accompanying drawings and descriptions of the embodiments or the prior art. Obviously, the following description of the structure of the accompanying drawings is only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. It should be noted that the description of these embodiments is for the purpose of helping to understand the present invention, but does not constitute a limitation of the present invention.

[0059] Example:

[0060] like Figures 1-14 As shown, this embodiment provides a machine tool for machining straight-profile toroidal worm gears, including a machine tool body 100, a drive assembly 200, a tool assembly 300, and a control assembly 400;

[0061] The drive assembly 200 is mounted on the machine tool body 100. The machine tool body 100 is provided with a tailstock 101 located on the opposite side of the drive assembly 200. Between the drive assembly 200 and the tailstock 101 is a worm clamping part for clamping the worm blank.

[0062] The tool assembly 300 is disposed on the machine tool body 100 and located on the side of the machine tool body 100. The tool assembly 300 includes a tool disc 31 that meshes with the worm blank. The tool disc 31 is provided with multiple turning groups. The turning groups are fixed at equal intervals along the circumferential direction of the tool disc 31 on the outer circumferential surface of the tool disc 31. Each turning group includes a bottom turning tool 51 for machining the bottom surface of the worm tooth groove, a left-cutting turning tool 52 for machining the left side surface of the worm, and a right-cutting turning tool 53 for machining the right side surface of the worm. The bottom turning tool 51, the left-cutting turning tool 52, and the right-cutting turning tool 53 are fixed at equal intervals along the circumferential direction of the tool disc 31.

[0063] The control component 400 is mounted on the machine tool body 100 and electrically connected to the drive component 200 and the tool component 300 respectively, so as to form a constant transmission ratio and achieve the optimal cutting speed.

[0064] To address the problems existing in the prior art, the cutter head 31 forms a meshing motion relationship with the worm blank through the turning assembly, and the cutter head 31 slides and rolls along the helical surface of the worm to form a fixed transmission ratio. Correspondingly, for the cutter head 31, through the arrangement of multiple turning assemblies, the cutter head 31 and multiple cutting tools 500 form a worm gear tooth profile cutter 500 similar to a worm gear. The cutter head 31 is equivalent to the worm gear body, and the cutting tools 500 are equivalent to the worm gear teeth. The worm tooth profile is cut out through the meshing motion of the worm gear tooth profile cutter 500 and the worm blank, and the machined worm is closer to the theoretical value of the worm.

[0065] Meanwhile, the drive assembly 200 can fix the worm blank on the machine tool body 100 and drive the worm blank to rotate, so as to cooperate with the tool assembly 300 to complete the cutting process. The control assembly 400 is used to control the drive assembly 200 and the tool assembly 300, specifically the rotation speed of the two, so as to form a constant transmission ratio and achieve the optimal cutting speed, thereby improving the quality of machining.

[0066] During operation, the operator places and clamps the worm blank on the machine tool body 100; then, the drive assembly 200 and tool assembly 300 are started to begin cutting. The feed depth is adjusted by the tool assembly 300. The bottom cutting tool 51 machines the bottom surface of the worm teeth, the left-side cutting tool 52 machines the left side of the worm, and the right-side cutting tool 53 machines the right side of the worm, thus machining the worm tooth profile. The transmission ratio and cutting speed are controlled by the control assembly 400 to improve the cutting quality. After machining is completed, the worm is removed and replaced with the next worm blank, and the above operation is repeated for re-machining.

[0067] Based on the above technical solution, this straight-profile toroidal worm turning machine tool solves the problem that the equipment used for machining straight-profile toroidal worms cannot meet the machining requirements of straight-profile toroidal worms by improving the structure of the tool assembly 300. Moreover, the machined worm is closer to the theoretical value of the worm and the machining quality is good.

[0068] The cutter head 31 is disc-shaped and equipped with three types of cutting tools 500: a bottom-cutting tool 51, a left-edge cutting tool 52, and a right-edge cutting tool 53. The bottom-cutting tool cuts out the basic shape of the worm gear. The cutting edges of the left-edge cutting tool 52 and the right-edge cutting tool 53 are straight, and the machined worm gear tooth surface is a non-developable ruled surface, which is closer to the theoretical value. At the same time, by setting multiple cutting groups, the number of times the worm gear blank is cut during one revolution of the cutter head 31 is increased, which greatly improves the machining efficiency. Moreover, each cutting tool 500 only has a single edge participating in the cutting, which helps to reduce the cutting force, improve the machining accuracy, and extend the service life of the tool 500.

[0069] Furthermore, during the machining process, 2-3 cutting tools 500 on the cutter head 31 participate in the cutting, resulting in smoother cutting and offsetting the impact of cutting force on the machining accuracy of the worm gear. In actual machining, the diameter of the cutter head 31 is appropriately increased or decreased according to the diameter of the worm gear to achieve the best cutting effect.

[0070] The cutting process will be further explained below with reference to the specific structure of each component of this straight-profile toroidal worm gear turning machine tool:

[0071] In this embodiment, the drive assembly 200 includes a spindle motor 201 and a spindle 202. The output end of the spindle motor 201 is connected to the spindle 202 through a first reducer 203. The spindle 202 is rotatably mounted on the machine tool body 100. Based on the above technical solution, the speed is reduced by the first reducer 203, which reduces the inertia of the load and achieves speed matching. At the same time, it transmits torque and can improve the output torque.

[0072] Preferably, the machine tool body 100 is provided with a housing or cover to shield the drive assembly 200, so as to avoid the adhesion and corrosion of dust and other impurities, thereby improving the service life of the various components inside the drive assembly 200. Furthermore, the drive assembly 200 has the advantages of simple structure and low cost.

[0073] During operation, the spindle motor 201 is started, and the driving force of the spindle motor 201 is transmitted to the spindle 202 through the first reducer 203. The spindle 202 rotates under the action of the driving force, and the chuck 204 set on the spindle 202 and the worm blank clamped on the chuck 204 also rotate. The rotation of the worm blank is the main motion in worm machining.

[0074] In one possible implementation, the tailstock 101 is slidably disposed on the machine tool body 100 and located on the opposite side of the spindle 202, and the gap between the tailstock 101 and the spindle 202 is the worm gear clamping part; and the spindle 202 is provided with a chuck 204 for clamping the worm gear blank, and the tailstock 101 is provided with a center point 102 for abutting the worm gear blank.

[0075] Based on the above technical solution, the sliding of the tailstock 101 can adjust the distance between the tailstock 101 and the chuck 204 to accommodate the processing requirements of worm gears of different lengths. Simultaneously, when the operator clamps the worm gear blank, one end of the blank is engaged with the chuck 204, and the other end abuts against the center 102. The sliding of the tailstock 101 facilitates the installation of the worm gear blank and the removal of the processed worm gear.

[0076] In this embodiment, the tool assembly 300 includes a tool assembly body 32 located on the machine tool body 100, a dial handle 33 rotatably mounted on the tool assembly body 32, and a motor 34 fixedly connected to the tool assembly body 32. The tool assembly body 32 is connected to the machine tool body 100 via a dovetail guide rail. The dial handle 33 and the motor 34 are located at opposite ends of the tool assembly body 32. The output end of the dial handle 33 is connected to the dovetail guide rail, and the output end of the motor 34 is connected to the tool disc 31 via a second reducer 35.

[0077] Based on the above technical solution, the tool assembly body 32 is the part of the tool assembly 300 that connects to the machine tool body 100, and it can be constructed into any suitable shape. The tool assembly body 32 provides installation space for components such as the dial handle 33 and the motor 34. At the same time, the tool assembly body 32 covers the dovetail guide rail. By rotating the dial handle 33, the tool assembly body 32 can move laterally on the machine tool body 100, thereby adjusting the distance between the cutter head 31 and the worm blank. This movement is the feed movement in worm machining, ultimately achieving the purpose of adjusting the depth of feed of the turning group and controlling the worm size. The driving force of the motor 34 is transmitted to the cutter head 31 through the second reducer 35. The cutter head 31 rotates under the action of this driving force, and the turning group set on the cutter head 31 also rotates. The rotation of the cutter head 31 is the generating movement in worm machining.

[0078] Furthermore, the function of the second reducer 35 is the same as that of the first reducer 203, and will not be repeated here. Meanwhile, any suitable commercially available model can be selected for both the first reducer 203 and the second reducer 35. In addition, the second reducer 35 improves the precision of the cutting process and also enhances the stability of the torque on the cutter head 31, thus contributing to improved machining quality.

[0079] During operation, the operator starts the motor 34 to rotate the cutter head 31 and operates the dial handle 33 to bring the cutter head 31 close to the worm blank, so that the turning assembly meshes with the worm blank. The cutter head 31 has three types of cutting tools 500: a bottom-cutting tool 51, a left-cutting tool 52, and a right-cutting tool 53. Each of the three tools processes different surfaces of the worm and works together to cut the worm tooth profile. The shape and size of the worm tooth surface are close to the theoretical state.

[0080] In this embodiment, the control component 400 includes a frequency converter module 410 and a fine-tuning module 420. The frequency converter module 410 includes a first frequency converter 411 electrically connected to the drive component 200 and a second frequency converter 412 electrically connected to the tool component 300. The fine-tuning module 420 includes a first fine-tuner 421 electrically connected to the first frequency converter 411, a second fine-tuner 422 electrically connected to the second frequency converter 412, and a master fine-tuner 423 electrically connected to both the first frequency converter 411 and the second frequency converter 412.

[0081] Specifically, the first frequency converter 411 is connected to the spindle motor 201, and the second frequency converter 412 is connected to the electric motor 34. Based on this, the rotational speeds of the spindle 202 and the cutter head 31 can be controlled by the frequency converter module 410. Furthermore, the first fine-tuner 421 controls the operation of the first frequency converter 411, and the second fine-tuner 422 controls the operation of the second frequency converter 412, forming a control chain. This facilitates adjustments by the operator to achieve any constant transmission ratio between the spindle 202 and the cutter head 31, meeting the needs of machining worm gears of different specifications. Moreover, the overall fine-tuner 423 simultaneously controls the operation of both the spindle motor 201 and the electric motor 34, ensuring optimal cutting speeds between the spindle 202 and the cutter head 31 to improve machining quality.

[0082] As is easy to understand, the first frequency converter 411 and the second frequency converter 412 can be any suitable commercially available frequency converter, and the first fine tuner 421, the second fine tuner 422 and the main fine tuner 4232 can be any suitable commercially available fine tuner.

[0083] In this embodiment, the cutter head 31 includes an upper cutter head 311 and a lower cutter head 312. The upper cutter head 311 is provided with an upper cutter head shaft hole 301 in the middle, and the lower cutter head 312 is provided with a lower cutter head shaft hole 302 in the middle. A plurality of tool fixing grooves 303 are evenly distributed around the lower cutter head 312 on the outer side of the lower cutter head shaft hole 302.

[0084] When the upper cutter head 311 is connected to the lower cutter head 312 by the first bolt 304, the upper cutter head shaft hole 301 and the lower cutter head shaft hole 302 are coaxial and connected to form a transmission hole. A rotating shaft 351 is installed through the transmission hole. The end of the rotating shaft 351 is connected to the upper cutter head 311 by the pressure plate 305. The rotating shaft 351 is connected to the lower cutter head 312 by the flat key 306.

[0085] Based on the above technical solution, the upper cutter head 311 and the lower cutter head 312 are connected as a whole by the first bolt 304. The cutter 500 is inserted into the cutter fixing groove 303 and pressed by the upper cutter head 311 to fix the cutter 500. A transmission hole is formed through the upper cutter head shaft hole 301 and the lower cutter head shaft hole 302. The transmission hole is connected to the rotating shaft 351, which is part of the second reducer 35. The torque is transmitted to the lower cutter head 312 through the flat key 306. The flat key 306 does not contact the upper cutter head 311 to avoid misalignment between the upper cutter head 311 and the lower cutter head 312.

[0086] like Figure 7 As shown, the end of the rotating shaft 351 is flush with the end face of the upper cutter head 311. The upper cutter head 311 is provided with a pressure plate 305, which is connected to the rotating shaft 351 by screws. At the same time, the pressure plate 305 applies pressure to the upper cutter head 311, which can increase the pressure on the tool 500 and increase the tightness between the upper cutter head 311 and the lower cutter head 312.

[0087] Optionally, such as Figure 9 As shown, a tool 500 is inserted into each tool fixing slot 303. The tool 500 is a slot bottom turning tool 51, a left-edge turning tool 52, or a right-edge turning tool 53. Based on this, the spacing between adjacent tools 500 is increased to ensure that only 2-3 tools 500 turn the worm blank at a time.

[0088] Preferably, the first bolt 304 is located between adjacent tool fixing slots 303, and the upper tool disc 311 is also provided with secondary bolts 307 for connecting the tools 500, with each tool 500 connected to two secondary bolts 307. Based on this, the secondary bolts 307 increase the connection points of the tools 500, making the tools 500 better fixed on the tool fixing slots 303 and preventing the tools 500 from being disturbed during the cutting process.

[0089] For the tool fixing slots, several tool fixing slots 303 are evenly distributed around the lower tool disc 312, with the tool fixing slots 303 centered on the lower tool disc shaft hole 302. In one possible implementation, the lower tool disc 312 has 12 tool fixing slots 303, and correspondingly, there are 4 turning groups: 4 bottom turning tools 51, 4 left-edge turning tools 52, and 4 right-edge turning tools 53. In each turning group, the bottom turning tool 51, the left-edge turning tool 52, and the right-edge turning tool 53 are sequentially fixed to the tool fixing slots 303 along the circumference of the tool disc 31. Based on the above design, the worm gear is cut 12 times per revolution of the tool disc 31, effectively improving cutting efficiency.

[0090] In this embodiment, a tool 500 is detachably provided in the tool fixing groove 303. The tool 500 includes a tool body 501, a tool core 502, a tool head 503 and a blade 504. The tool core 502 is inserted into the tool body 501 and extends to the outside of one end of the tool body 501. The tool body 501 is provided with a scale 505 at that end.

[0091] The cutter head 503 includes a column 503a adapted to the dial 505 and a base 503b for placing the blade 504. One side of the column 503a is provided with a slot adapted to the blade core 502, and the other side of the column 503a is connected to the base 503b. The column 503a is also provided with a connecting groove 506 located on the side of the base 503b. A second bolt 507 is detachably provided on the connecting groove 506. Correspondingly, the dial 505 is provided with a connecting hole adapted to the second bolt 507.

[0092] The top surface of the base 503b is adapted to the placement surface of the blade 504. The blade 504 is connected to the base 503b by the third bolt 508. The blade 504 is provided with a pressure block 509, and the pressure block 509 is connected to the base 503b by the fourth bolt 510.

[0093] The insert 504 has multiple working surfaces, one of which is provided with a cutting edge 511 to form the groove bottom turning tool 51, left-edge turning tool 52, or right-edge turning tool 53, respectively.

[0094] Based on the above technical solution, most of the tool body 501 is inserted into the tool fixing groove 303. The shape of the tool body 501 is adapted to the tool fixing groove 303 to increase the contact area between the two, thereby improving stability and reducing disturbance. The tool core 502 is installed inside the tool body 501 and connects the tool body 501 and the tool head 503, which helps to improve the rigidity of the tool 500 and expand its application range. The tool head 503 is divided into a post 503a connecting the tool body 501 and a support 503b for placing the insert 504. The insert 504 is fixed to the support 503b by a third bolt 508. A pressure block 509 is provided above the insert 504 to tighten the third bolt 508, achieving secondary tightening to ensure that the insert 504 will not be disturbed during turning.

[0095] The insert 504 is equipped with a cutting edge 511. By defining the working surface where the cutting edge 511 is located, a bottom-cutting tool 51, a left-hand cutting tool 52, or a right-hand cutting tool 53 can be manufactured respectively. Based on this, a modular design is achieved, simplifying the structure of the tool 500 and effectively reducing the economic cost of the tool 500. Furthermore, the shape of the support 503b is adapted to the shape of the insert 504, extending the service life of the insert 504 while ensuring the cutting effect.

[0096] In actual use, given a fixed specification, multiple sets of the blade body 501 and blade core 502 can be prepared for a single specification, and at least two types of blade heads 503 can be prepared based on the shape of the blade 504, to ensure normal use.

[0097] Furthermore, the cutting tool 500 and the cutter head 31 are detachably connected, and the cutting tool 500 is also constructed as a detachable structure. Depending on the worm module and envelope angle, different sizes of cutter heads 31 can be replaced, the number of cutting tools 500 can be increased or decreased, or the cutting head 503 can be replaced, providing a variety of solutions. This not only adapts to the machining of worms with different modules, but also improves the ease of use and ensures the machining quality.

[0098] Preferably, the blade core 502 is made of cemented carbide, which has a series of excellent properties such as high hardness, wear resistance, good strength and toughness, heat resistance, and corrosion resistance, especially its high hardness and wear resistance. Alternatively, the blade core 502 can also be made of any other suitable material.

[0099] In one possible implementation, the connecting groove 506 is constructed as an arc-shaped groove, allowing the cutter head 503 to rotate relative to the cutter body 501 with the cutter core 502 as the center. The maximum range of rotation is the arc length of the arc-shaped groove. The outer periphery of the dial 505 is provided with a scale 512 for displaying angles. Based on the above technical solution, by allowing the cutter head 503 and the cutter body 501 to rotate relative to each other, the angle of the cutter 500 can be changed according to the worm module and lead to meet the machining needs of different helix angles, adapt to the machining of worms with different modules, and expand the range of applications.

[0100] Preferably, a scale 512 is provided on the outside of the dial 505 to help the operator grasp the value of the actual rotation angle, so as to meet the requirements of precise processing and help improve the processing quality.

[0101] Optionally, the cutting head 503 can rotate within a range of ±10° relative to the cutting body 501.

[0102] In one possible implementation, the dial 505 has a first end face tooth on its side, and correspondingly, the pillar 503a has a second end face tooth adapted to the first end face tooth on its side. Based on the above technical solution, when the tool body 501 is connected to the tool head 503, the first end face tooth and the second end face tooth mesh with each other to form a firm positional relationship, satisfying the connection requirements of the two, reducing the probability of the tool head 503 misaligning relative to the tool body 501 during turning, and ensuring the quality of turning.

[0103] Regarding the shape of the cutter head 503, the following feasible implementation schemes are listed:

[0104] In one possible implementation, such as Figures 10-13As shown, when forming the left-edge cutting tool 52 or the right-edge cutting tool 53, the insert 504 has an asymmetrical triangular structure, and the cutting edge 511 is located on the side of the asymmetrical triangular structure.

[0105] In another possible implementation, such as Figure 14 As shown, when forming the groove bottom cutting tool 51, the insert 504 has a rectangular structure, and the cutting edge 511 is located on the front end face of the rectangular structure.

[0106] Based on the above technical solution, the structure of the blade 504 is simplified, manufacturing costs are reduced, and materials are saved. Furthermore, it is easy to understand that the shape of the support 503b is also constructed as an asymmetrical triangular or rectangular structure.

[0107] Optionally, the gyration radius of the bottom-cutting tool 51 is the sum of the radius of the cutter head 31 and the worm gear tooth tip clearance, while the gyration radii of the left-cutting tool 52 and the right-cutting tool 53 are both the radius of the cutter head 31. Based on this, it is ensured that each of the three tools 500 cuts its designed machining surface, and that the three tools 500 do not simultaneously machine three machining surfaces during the cutting process. This reduces the single-tooth cutting force, lowers the probability of tool breakage, and extends tool life.

[0108] Optionally, the rake angle of the cutting edge 511 is 24°-26°, and the clearance angle of the cutting edge 511 is 4°-6°. Based on this, on the one hand, the sharpness and strength of the insert 504 are guaranteed, and on the other hand, the shape of the chip groove is more rounded, the cutting friction is smaller, the wear of the insert 504 is reduced, and the chips generated during the cutting process are easier to remove, reducing chip residue.

[0109] Preferably, the rake angle of the cutting edge 511 is 25° and the clearance angle of the cutting edge 511 is 5°.

[0110] This embodiment introduces a method for machining straight-profile toroidal worm gears based on the aforementioned machine tool for machining straight-profile toroidal worm gears. The method includes the following steps:

[0111] S100 connection: The worm blank is clamped by the straight profile toroidal worm gear turning machine tool;

[0112] S200 Turning: Start the straight profile toroidal worm turning machine tool to process the worm blank into a worm;

[0113] The turning process includes the following movements:

[0114] Main motion: The worm blank is rotated via the drive assembly 200;

[0115] Generating motion: The cutter head 31 rotates and forms a meshing motion relationship with the worm blank. For every 1 revolution of the worm blank, the cutter head 31 rotates K / Z times, where K is the number of worm threads and Z is the number of cutters 500 on the cutter head 31.

[0116] Feed motion: Driven by the tool assembly 300, the cutter head 31 makes a vertical feed motion along the radial direction of the worm blank to cut out the full tooth width of the worm.

[0117] Step S200 turning includes the following steps:

[0118] S201: Start the drive assembly 200 and the tool assembly 300. The drive assembly 200 drives the worm blank to rotate, and the tool assembly 300 drives the cutter head 31 to rotate.

[0119] S202: The control component 400 causes the cutter head 31 and the worm gear blank to rotate relative to each other according to a fixed transmission ratio;

[0120] S203: The bottom cutting tool 51, the left cutting tool 52, and the right cutting tool 53 sequentially turn the bottom surface of the worm tooth groove, the left side surface of the worm, and the right side surface of the worm.

[0121] S204: The tool assembly 300 drives the tool head 31 to perform transverse feed.

[0122] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A machine tool for machining straight-profile toroidal worm gears, characterized in that, It includes a machine tool body (100), a drive assembly (200), a tool assembly (300), and a control assembly (400); The drive assembly (200) is mounted on the machine tool body (100), and the machine tool body (100) is provided with a tailstock (101) located on the opposite side of the drive assembly (200). Between the drive assembly (200) and the tailstock (101) is a worm clamping part for clamping the worm blank. The tool assembly (300) is set on the machine tool body (100) and located on the side of the machine tool body (100). The tool assembly (300) includes a cutter head (31) that meshes with the worm blank. The cutter head (31) is provided with multiple turning groups. The turning groups are fixed at equal intervals along the circumferential direction of the cutter head (31) on the outer circumferential surface of the cutter head (31). Each turning group includes a bottom turning tool (51) for machining the bottom surface of the worm tooth groove, a left-cutting turning tool (52) for machining the left side surface of the worm, and a right-cutting turning tool (53) for machining the right side surface of the worm. The bottom turning tool (51), the left-cutting turning tool (52), and the right-cutting turning tool (53) are fixed at equal intervals along the circumferential direction of the cutter head (31) on the cutter head (31). The control component (400) is mounted on the machine tool body (100) and electrically connected to the drive component (200) and the tool component (300) respectively, so as to form a constant transmission ratio and achieve the optimal cutting speed.

2. The machine tool for machining straight-profile toroidal worm gears according to claim 1, characterized in that, The drive assembly (200) includes a spindle motor (201) and a spindle (202). The output end of the spindle motor (201) is connected to the spindle (202) through a first reducer (203). The spindle (202) is rotatably mounted on the machine tool body (100). The tailstock (101) is slidably disposed on the machine tool body (100) and located on the opposite side of the spindle (202). The gap between the tailstock (101) and the spindle (202) is the worm clamping part. The spindle (202) is provided with a chuck (204) for clamping the worm blank, and the tailstock (101) is provided with a center point (102) for abutting the worm blank.

3. The machine tool for machining straight-profile toroidal worm gears according to claim 1, characterized in that, The tool assembly (300) includes a tool assembly body (32) located on the machine tool body (100), a dial handle (33) rotatably mounted on the tool assembly body (32), and a motor (34) fixedly connected to the tool assembly body (32). The tool assembly body (32) is connected to the machine tool body (100) via a dovetail guide rail. The dial handle (33) and the motor (34) are located at opposite ends of the tool assembly body (32). The output end of the dial handle (33) is connected to the dovetail guide rail, and the output end of the motor (34) is connected to the tool disc (31) via a second reducer (35).

4. The machine tool for machining straight-profile toroidal worm gears according to claim 1, characterized in that, The control component (400) includes a frequency converter module (410) and a fine-tuning module (420). The frequency converter module (410) includes a first frequency converter (411) electrically connected to the drive component (200) and a second frequency converter (412) electrically connected to the tool component (300). The fine-tuning module (420) includes a first fine-tuner (421) electrically connected to the first frequency converter (411), a second fine-tuner (422) electrically connected to the second frequency converter (412), and a master fine-tuner (423) electrically connected to both the first frequency converter (411) and the second frequency converter (412).

5. The machine tool for machining straight-profile toroidal worm gears according to any one of claims 1-4, characterized in that, The cutter head (31) includes an upper cutter head (311) and a lower cutter head (312). The upper cutter head (311) has an upper cutter head shaft hole (301) in the middle, and the lower cutter head (312) has a lower cutter head shaft hole (302) in the middle. Several tool fixing grooves (303) are evenly distributed around the lower cutter head (312) on the outer side of the lower cutter head shaft hole (302). When the upper cutter head (311) is connected to the lower cutter head (312) by the first bolt (304), the shaft hole (301) of the upper cutter head and the shaft hole (302) of the lower cutter head are coaxial and connected to form a transmission hole. A rotating shaft (351) is installed on the transmission hole. The end of the rotating shaft (351) is connected to the upper cutter head (311) by a pressure plate (305). The rotating shaft (351) is connected to the lower cutter head (312) by a flat key (306).

6. The machine tool for machining straight-profile toroidal worm gears according to claim 5, characterized in that, A tool (500) is detachably provided in the tool fixing groove (303). The tool (500) includes a tool body (501), a tool core (502), a tool head (503), and a blade (504). The tool core (502) is inserted into the tool body (501) and extends to the outside of one end of the tool body (501). The tool body (501) is provided with a scale (505) at that end. The cutting head (503) includes a column (503a) adapted to the dial (505) and a base (503b) for placing the cutting blade (504). One side of the column (503a) is provided with a slot adapted to the cutting core (502), and the other side of the column (503a) is connected to the base (503b). The column (503a) is also provided with a connecting groove (506) located on the side of the base (503b). A second bolt (507) is detachably provided on the connecting groove (506). Correspondingly, the dial (505) is provided with a connecting hole adapted to the second bolt (507). The top surface of the base (503b) is adapted to the placement surface of the blade (504). The blade (504) is connected to the base (503b) by the third bolt (508). The blade (504) is provided with a pressure block (509). The pressure block (509) is connected to the base (503b) by the fourth bolt (510). The insert (504) has multiple working surfaces, one of which is provided with a cutting edge (511) to form the groove bottom turning tool (51), left-hand turning tool (52), or right-hand turning tool (53), respectively.

7. The machine tool for machining straight-profile toroidal worm gears according to claim 6, characterized in that, The first bolt (304) is located between adjacent tool fixing slots (303). The upper tool disc (311) is also provided with auxiliary bolts (307) for connecting the tools (500), and each tool (500) is connected to two auxiliary bolts (307).

8. The machine tool for machining straight-profile toroidal worm gears according to claim 6, characterized in that, The connecting groove (506) is constructed as an arc groove so that the cutting head (503) can rotate relative to the cutting body (501) with the cutting core (502) as the center. The maximum range of rotation is the arc length of the arc groove. The outer periphery of the dial (505) is provided with a scale (512) for displaying the angle. The dial (505) has a first end face tooth on its side, and correspondingly, the column (503a) has a second end face tooth adapted to the first end face tooth on its side.

9. The machine tool for machining straight-profile toroidal worm gears according to claim 8, characterized in that, When forming the left-edge turning tool (52) or the right-edge turning tool (53), the insert (504) has an asymmetrical triangular structure, the cutting edge (511) is located on the side of the asymmetrical triangular structure, and the rake angle of the cutting edge (511) is 24°-25°, and the clearance angle of the cutting edge (511) is 4°-6°. When forming the groove bottom turning tool (51), the insert (504) has a rectangular structure, and the cutting edge (511) is located on the front end face of the rectangular structure.

10. A method for machining a straight-profile toroidal worm gear, characterized in that, Includes the following steps: Connection: The worm blank is clamped in a straight-profile toroidal worm turning machine tool as described in any one of claims 1-9; Turning: Start the straight profile toroidal worm turning machine tool to process the worm blank into a worm; The step-turning process includes the following movements: Main motion: The worm blank is rotated by the drive assembly (200); Generating motion: The cutter head (31) rotates and forms a meshing motion relationship with the worm blank. For every 1 revolution of the worm blank, the cutter head (31) rotates K / Z revolutions, where K is the number of worm threads and Z is the number of cutters (500) on the cutter head (31). Feed motion: Driven by the tool assembly (300), the cutter head (31) makes a vertical feed motion along the radial direction of the worm blank to cut out the full tooth width of the worm; Step-turning includes the following steps: Start the drive assembly (200) and the tool assembly (300). The drive assembly (200) drives the worm blank to rotate, and the tool assembly (300) drives the cutter head (31) to rotate. The control component (400) causes the cutter head (31) and the worm blank to rotate relative to each other according to a fixed transmission ratio; The bottom cutting tool (51), the left cutting tool (52), and the right cutting tool (53) sequentially turn the bottom surface of the worm tooth groove, the left side surface of the worm, and the right side surface of the worm. The tool assembly (300) drives the tool head (31) to perform transverse feed.

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