A fan gear composite machining device and machining method

Abstract

The present application belongs to the field of gear machining, and particularly relates to a sector gear composite machining device and machining method. The device comprises a gear shaping cutter handle, a sector gear shaping cutter, a base, a clamp cone, a positioning expansion sleeve, a cover plate and a compression bolt. The base is arranged on a machine tool, and the clamp cone is arranged at the center of the base. The outer side surface of the clamp cone is a conical surface, and a threaded hole is arranged at the center of the upper end surface of the clamp cone. The inner hole of the expansion sleeve is a conical hole matched with the conical surface. The expansion sleeve is arranged on the clamp cone, and the cover plate is arranged above the expansion sleeve. The part to be machined is arranged outside the expansion sleeve and placed on the base. The compression bolt is screwed into the threaded hole of the clamp cone through the cover plate, so that the expansion sleeve and the clamp cone are compressed tightly through the cover plate. The positioning expansion sleeve is expanded through the conical surface matching, and the part to be machined is positioned by the expanded positioning expansion sleeve. The sector gear shaping cutter is installed on the gear shaping cutter handle through a screw, and the gear shaping cutter has a two-side sector structure.

Description

Technical Field

[0001] This invention belongs to the field of gear processing, and specifically relates to a sector gear composite processing device and processing method. Background Technology

[0002] A sector gear is a gear structure designed with angles along its circumference. As a commonly used mechanical transmission element, it has wide applications in various fields. Common sector gear parts include sector gears with conventional angle designs, sector gears with bosses on both sides, and multi-spindle sector gears. Conventional gear shaping methods cause interference when machining the bosses on both sides. These parts are often processed using wire cutting, resulting in an electrolytic corrosion layer on the tooth surface and low machining efficiency. Furthermore, for compact double gears or double sector gears, parts requiring high positional accuracy in the tooth angle direction are relatively difficult to machine due to their structural limitations, making wire cutting and other similar processes challenging to implement. Summary of the Invention

[0003] The purpose of this invention is to provide a composite machining device and method for sector gears, which can solve the machining problems of such parts and improve the machining accuracy of such parts.

[0004] The technical solution of this invention is as follows:

[0005] A sector gear composite machining device includes: a gear shaping tool holder, a sector gear shaping tool, a base, a clamping cone, a positioning expansion sleeve, a cover plate, and clamping bolts;

[0006] The base is mounted on the machine tool, and a clamping cone is set at the center of the base. The outer side of the clamping cone is a conical surface, and a threaded hole is provided at the center of the upper end face of the clamping cone. The inner hole of the expansion sleeve is a conical hole that mates with the conical surface. The expansion sleeve is fitted onto the clamping cone, and a cover plate is set above the expansion sleeve. The workpiece to be processed is fitted onto the expansion sleeve and placed on the base. The clamping bolt passes through the cover plate and is screwed into the threaded hole of the clamping cone, thereby pressing the expansion sleeve and the clamping cone together through the cover plate. The positioning expansion sleeve is expanded open through the conical surface mating, and the positioning expansion sleeve is tightened to position the workpiece to be processed.

[0007] The fan-shaped gear shaping cutter is mounted on the gear shaping cutter shank by screws, and the gear shaping cutter consists of a fan-shaped structure on both sides.

[0008] Furthermore, the sector-shaped gear shaper cutter has two sets of teeth, with the parameters of the two sets of teeth being the same or different. The tooth gap width between the two sets of teeth is reasonably given according to factors such as the cutter diameter and the number of teeth of the sector gear to ensure the effective number of teeth for the sector gear during shaping, while avoiding gear interference. The tooth gap width between the two sets of teeth is 4-8 times the tooth pitch width. When the parameters of the two sets of teeth are different, the tooth pitch width is 4-8 times that of the tooth with the larger module.

[0009] Furthermore, the lower end face of the gear shaping tool holder is provided with a keyway, and a positioning end key is installed in the keyway; the upper end face of the fan-shaped gear shaping tool is provided with a positioning groove.

[0010] The sector-shaped gear cutter is positioned circumferentially by engaging a positioning groove with a positioning end key.

[0011] Furthermore, the base is provided with a positioning pin, which is used for angular positioning of the part to be processed.

[0012] Furthermore, the upper end face of the expansion sleeve has N grooves extending axially downwards through the inner and outer surfaces of the expansion sleeve;

[0013] The lower end face of the expansion sleeve has N grooves that extend axially upward through the inner and outer surfaces of the expansion sleeve.

[0014] The grooves at 2N are evenly distributed circumferentially; the lengths of the grooves at 2N are equal and do not exceed the height of the expansion sleeve.

[0015] Furthermore, the width of the groove at 2N is generally 0.5mm-2mm, which can be adjusted appropriately according to the positioning diameter; the length is 80%-90% of the expansion sleeve height; and the grooves at both ends are evenly distributed.

[0016] A method for compound machining of sector gears, the method being implemented by the aforementioned device, the method comprising: two sets of teeth on a sector gear shaper having identical parameters and having a co-directional rake face structure; one set of teeth being used for roughing teeth, and the other set of teeth being used for finishing teeth.

[0017] Furthermore, the method also includes: the parameters of the two sets of teeth of the fan-shaped gear shaper are different and the rake faces are in the same direction;

[0018] One set of teeth is used to machine one type of sector gear, and another set of teeth is used to machine another type of sector gear; the two types of sector gears are machined separately using the same sector gear shaper, thereby improving the gear alignment accuracy of the two types of sector gears.

[0019] The beneficial effects of this invention are:

[0020] A composite machining device and method for sector gears enables gear shaping, avoiding interference between the bosses on both sides of the sector gear. It allows for rough and fine gear shaping on different parts using a single tool. It enables single-clamp gear shaping of sector gears or multi-gear sets with different parameters, ensuring strict tooth angle accuracy of the reference teeth in multi-gear sets. The symmetry of the reference teeth in such parts is improved from 0.2mm to 0.02mm, with stable quality and high precision. The device is compact, provides stable quality, and has high processing efficiency, solving practical technical problems in production. Attached Figure Description

[0021] To more clearly illustrate the specific embodiments of the present invention, the accompanying drawings will be described below.

[0022] Figure 1Axonometric drawing of a sector gear machining apparatus;

[0023] Figure 2 This is a cross-sectional view of a sector gear machining device;

[0024] Figure 3 An exploded view of the sector gear machining device;

[0025] Figure 4 This is a schematic diagram of step one of the gear hobbing process;

[0026] Figure 5 This is a schematic diagram of step two in the gear hobbing process;

[0027] Figure 6-9 This is a schematic diagram of a sector gear component; Detailed Implementation

[0028] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0029] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0030] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0031] Example 1

[0032] Please see Figure 1-9As shown, a sector gear composite machining device and machining method includes a gear shaping tool holder 1, a positioning end key 2, a sector gear shaping tool 3, a washer 4, a mounting screw 5, a clamping bolt 6, a cover plate 7, a positioning expansion sleeve 8, a fixture cone 9, a positioning pin 10, and a base 11.

[0033] A positioning key 2 is installed in the keyway on the lower end face of the gear shaping tool holder 1; the fan-shaped gear shaping tool 3 is installed on the lower end face of the gear shaping tool holder 1, and the fan-shaped gear shaping tool 3 cooperates with the positioning key 2 on the lower end face of the gear shaping tool holder 1; the keyway of the fan-shaped gear shaping tool 3 cooperating with the positioning key 2 is aligned with the reference tooth of the fan-shaped gear shaping tool 3, and the symmetry is within 0.01mm, thereby ensuring the strict angular installation position of the reference tooth of the fan-shaped gear shaping tool 3; a washer 4 is installed on the lower end face of the fan-shaped gear shaping tool 3; the mounting screw 5 is connected to the internal thread of the gear shaping tool holder 1, and the fan-shaped gear shaping tool 3 is fastened to the lower end of the gear shaping tool holder 1.

[0034] The positioning pin 10 is mounted on the base 11, and the outer circle of the positioning pin 10 mates with the inner hole of the base 11. The clamping cone 9 is mounted on the base 11, and the outer circle of the clamping cone 9 mates with the inner hole of the base 11. The positioning expansion sleeve 8 is mounted on the clamping cone 9. The positioning expansion sleeve 8 has four slots at each end, and the width of the slots is generally 0.5mm-2mm, which can be adjusted appropriately according to the positioning diameter. The length of the slots is 80%-90% of the height of the expansion sleeve. The eight slots at both ends are evenly distributed. The inner conical hole of the positioning expansion sleeve 8 mates with the outer conical surface of the clamping cone 9. The cover plate 7 is mounted on the upper end face of the positioning expansion sleeve 8. The external thread of the clamping bolt 6 is connected to the internal thread of the clamping cone 9, forming a complete clamp. The inner hole of the gear part to be processed fits with the outer circle of the positioning expansion sleeve 8. The lower end face of the gear part to be processed fits with the upper end face of the base 11. Tighten the clamping bolt 6, and the clamping force presses the positioning expansion sleeve 8 through the cover plate 7. Through the fit of the inner and outer conical surfaces, the positioning expansion sleeve 8 expands, realizing the positioning and clamping of the inner hole of the part without gap. The positioning pin 10 performs the angular positioning of the part.

[0035] When using this application, please refer to [link / reference]. Figures 1-9 As shown. A sector gear composite machining device and machining method, see [reference]. Figure 4 and Figure 5 As shown, the fan-shaped gear shaper uses the same tool parameters and the same rake face structure on both sides of the fan-shaped part. One side of the fan-shaped part can be used for rough cutting, and the other side can be used for fine cutting, which improves the stability of part accuracy and tool life.

[0036] The tool adopts a fan-shaped gear shaping tool structure, which has two sets of teeth. The two sets of teeth can use the same tooth parameters or different tooth parameters. When the two sets of teeth have the same parameters, the two sides of the tool are mostly symmetrically distributed. When the two sets of tooth parameters are different, the number of teeth on both sides of the tool can be reasonably allocated according to the structure of the workpiece to be processed, the fan-shaped angle, and considering factors such as tool wear. An asymmetrical structure can be adopted.

[0037] The missing tooth width between the two sets of teeth of the sector gear shaper should be reasonably determined according to factors such as the tool diameter and the number of teeth of the workpiece to be processed. The two sides of the tool should ensure the effective number of teeth for the gear shaping of the workpiece, while avoiding interference with the processing of non-machined parts on both sides of the sector gear.

[0038] See Figure 6 For the part shown, the number of teeth on both sides of the fan-shaped gear shaper is the same as the number of tooth grooves in the fan-shaped part of the part to be machined. This is done when the space on both sides of the fan-shaped part of the part to be machined allows, such as... Figure 9 For the sector gear section at the upper end of the part shown, the number of tool teeth can be appropriately increased; when the tool wears during machining, tooth offset adjustment can be used to adjust the starting teeth of the tool and extend the tool life.

[0039] By using a sector-shaped gear shaping tool in conjunction with a fixed-angle gear shaping programming method, the starting angle of the tool and the starting angle of the workpiece are adjusted, and the local teeth of the tool are controlled to participate in the cutting of the local teeth of the part. The sector-shaped part of the tool reciprocates and meshes with the part within a given angle range. Alternatively, a fixed-starting-point unidirectional rotational meshing motion can be used to effectively ensure the machining of the sector-shaped teeth of the part and solve the problem of sector gear machining.

[0040] See Figure 6 The symmetry between the locating groove on the end face of the sector gear shaper and the reference tooth of the sector gear shaper is within 0.01mm. The sector gear shaper is positioned in a strict circumferential angular direction by engaging with the key on the locating end of the tool holder through the locating groove on the end face. At the same time, the part to be processed is fixed in a fixed position by means of locating pins and other measures. By reasonably setting the starting angle of the workpiece and the starting angle of the tool in the gear shaping program, the strict tooth alignment accuracy of the reference tooth of the sector gear part is achieved.

[0041] See Figure 8 and Figure 9 The part shown can be machined into two types of sector gears in a single setup using both sides of a sector gear shaper cutter. The two sector sections of the cutter employ different tool parameters and a co-directional rake face structure. One side of the cutter can be used to machine the tooth profile of one type of sector gear, while the other side is used for the other type. By strictly matching the reference teeth on both sides of the cutter and adjusting the machining starting angle based on the measured values ​​of the first piece, the symmetry of the reference teeth A and B of the two sector gears on the part can be stably maintained within 0.02mm.

[0042] The advantages of this application are:

[0043] 1. This application utilizes a sector gear composite machining device and machining method to achieve effective tooth profile machining of sector gears and avoid interference between the bosses on both sides of the part when inserting teeth.

[0044] 2. Using this application, double sector gears and double gears can be processed in a single clamping operation, solving the technical problem of machining compact multi-sector gears and multi-gears, and improving processing efficiency.

[0045] 3. Using this application, the symmetry accuracy between the double sector gear and the reference teeth of the double gear is greatly improved, and the tooth setting accuracy is increased from 0.1-0.2mm to 0.02mm, solving the technical problem of tooth machining in actual production.

[0046] 4. This application has a reasonable structure, is flexible in operation, and can simplify the structure of the tooth positioning fixture and reduce the fixture cost.

[0047] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

[0048] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for composite machining of sector gears, wherein the method is implemented by a composite machining device for sector gears, characterized in that: The device includes: a gear hobbing tool holder, a fan-shaped gear hobbing tool, a base, a clamping cone, a positioning expansion sleeve, a cover plate, and a clamping bolt; The base is mounted on the machine tool, and a clamping cone is set at the center of the base. The outer side of the clamping cone is a conical surface, and a threaded hole is provided at the center of the upper end face of the clamping cone. The inner hole of the positioning expansion sleeve is a conical hole that mates with the conical surface. The positioning expansion sleeve is fitted onto the clamping cone, and a cover plate is set above the positioning expansion sleeve. The part to be processed is fitted onto the positioning expansion sleeve and placed on the base. The clamping bolt passes through the cover plate and is screwed into the threaded hole of the clamping cone, thereby pressing the positioning expansion sleeve and the clamping cone together through the cover plate. The positioning expansion sleeve is expanded open through the conical surface mating, and the positioning expansion sleeve tightens to position the part to be processed. The fan-shaped gear shaping cutter is mounted on the gear shaping cutter shank by screws, and the fan-shaped gear shaping cutter is composed of two fan-shaped structures on both sides; The fan-shaped gear shaper has two sets of teeth symmetrically arranged, and the parameters of the two sets of teeth are the same or different; when the parameters of the two sets of teeth of the fan-shaped gear shaper are the same and the rake face is in the same direction; one set of teeth is used for rough cutting teeth and the other set of teeth is used for finish cutting teeth; by adjusting the starting angle of the tool and the starting angle position of the workpiece, the local teeth of the tool are controlled to participate in the cutting of the local teeth of the workpiece, and the fan-shaped part of the tool reciprocates with the workpiece within a given angle range, or adopts a fixed starting point unidirectional rotational meshing motion; When the parameters of the two sets of teeth of a sector gear shaper are different and the rake faces are in the same direction, one set of teeth is used to process one type of sector gear and the other set of teeth is used to process another type of sector gear. By using the same sector gear shaper to process the two types of sector gears separately, the tooth alignment accuracy of the two types of sector gears can be improved.

2. The method according to claim 1, characterized in that: The tooth gap width between the two sets of teeth of the fan-shaped tooth shearing cutter is 4-8 times the tooth pitch width.

3. The method according to claim 2, characterized in that: The lower end face of the gear shaping tool holder is provided with a keyway, and a positioning end key is installed in the keyway; the upper end face of the fan-shaped gear shaping tool is provided with a positioning groove. The sector-shaped gear shaper is positioned circumferentially by engaging a positioning groove with a positioning end key.

4. The method according to claim 3, characterized in that: The base is provided with a positioning pin, which is used for angular positioning of the part to be processed.

5. The method according to claim 4, characterized in that: The upper end face of the positioning expansion sleeve has N grooves that penetrate the inner and outer surfaces of the positioning expansion sleeve along the axial direction downward. The lower end face of the positioning expansion sleeve has N grooves that extend axially upward through the inner and outer surfaces of the positioning expansion sleeve. The grooves at 2N are evenly distributed circumferentially; the lengths of the grooves at 2N are equal and do not exceed the height of the positioning expansion sleeve.

6. The method according to claim 5, characterized in that: The width of the groove at 2N is 0.5mm-2mm, and the length is 80%-90% of the height of the positioning expansion sleeve; the grooves at both ends are evenly distributed.

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