A method for directional control of gear generating grinding process parameters to address tooth surface deviation

Abstract

This invention discloses a method for directional control of gear generating grinding process parameters to address tooth surface deviation. The method includes the following steps: 1) collecting sensitive frequencies; 2) determining the target frequency and boundary frequency among the sensitive frequencies; 3) determining the adjustment target and boundary; 4) listing the minimum amplitude and direction of process parameter adjustment; 5) establishing a tooth surface deviation simulation model; 6) calculating the amplitude change rate of the target frequency and boundary frequency under each adjustment direction; 7) determining the adjustment range, direction, and magnitude of the process parameters; and 8) conducting experimental verification. The technical solution provided by this invention uses abnormal frequencies in historical Fourier transform data as sensitive frequencies. Based on the tooth surface deviation simulation model, it quantitatively calculates the amplitude change rate of each sensitive frequency under each process parameter adjustment direction, determining the process parameter adjustment direction. This can improve the efficiency of gear batch production and reduce production costs.

Description

Technical Field

[0001] This invention relates to the field of grinding technology, and in particular to a method for directional control of gear generating grinding process parameters to address tooth surface deviations. Background Technology

[0002] For transmission systems in high-end equipment such as aerospace and new energy vehicles, the tooth surface deviation of high-speed gears directly affects gear transmission errors, thus impacting gear meshing noise, fatigue life, and other service life parameters. Tooth surface deviation refers to the geometric deviation between the actual tooth surface of a machined gear and its theoretical tooth surface, encompassing macroscopic, mesoscopic, and microscopic geometric characteristics. Currently, Fourier transform testing is commonly used at Klingberg or Gleason gear testing centers to analyze tooth surface deviation.

[0003] Generating grinding is a primary finishing process for high-speed gears, involving numerous process parameters such as linear velocity, feed rate, feed percentage, tool runout, dressing linear velocity, dressing amount, and coolant jet flow rate. These generating grinding process parameters directly or indirectly alter tooth surface deviations, resulting in numerous influencing factors and multiple optimization directions. Furthermore, as the primary carrier of generating grinding, the worm gear grinding machine has a complex structure, containing three linear axes and three rotary axes. The complex dynamic characteristics of the machine tool, such as system vibration, machine tool errors, and tool condition, also directly or indirectly alter tooth surface deviations. In addition, there are interrelationships between generating grinding process parameters and the complex dynamic characteristics of the machine tool, leading to numerous factors affecting tooth surface deviations, and the formation mechanism of tooth surface deviations is extremely complex.

[0004] To improve tooth surface deviation, process parameters can be directly adjusted in the machine tool operating system, or the dynamic characteristics of the machine tool can be improved by repairing machine tool hardware and adjusting machine tool geometric errors. Considering cost and efficiency, direct adjustment of process parameters is the most ideal. Furthermore, adjusting process parameters such as linear speed, feed rate, and feed percentage can often solve the problem of unqualified tooth surface deviation detection. Therefore, it is necessary to find the direction for adjusting the process parameters of generating grinding to improve the efficiency of gear mass production and reduce production costs. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a method for directional control of gear generating grinding process parameters oriented towards tooth surface deviation, so as to improve the efficiency and economy of controlling tooth surface deviation in generating grinding.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] A method for directional control of gear generating grinding process parameters oriented towards tooth surface deviation uses abnormal frequencies in historical Fourier transform data as sensitive frequencies. Based on a tooth surface deviation simulation model, the method quantitatively calculates the amplitude change rate of each sensitive frequency under the adjustment direction of each process parameter, and determines the adjustment direction of the process parameter. The method includes the following steps:

[0008] 1) Based on historical processing data, collect abnormal frequencies from the gear Fourier transform test results and use these abnormal frequencies as sensitive frequencies;

[0009] 2) Based on the gear Fourier transform test results, determine the target frequency and boundary frequency among the sensitive frequencies;

[0010] 3) Determine the adjustment target and adjustment boundary according to the gear Fourier quality inspection requirements;

[0011] 4) Based on engineering experience, determine the minimum range and direction of adjustment for process parameters;

[0012] 5) Input the process parameters for each group, establish a set of simulation models of the tooth surface morphology of generating grinding, and extract the tooth surface deviation and corresponding Fourier spectrum respectively;

[0013] 6) Calculate the rate of change of the amplitude of the target frequency and the boundary frequency under different adjustment directions, and calculate the rate of change of the amplitude of the sensitive frequency by the process parameters under a unit adjustment range;

[0014] 7) Determine the adjustment range of process parameters based on the production cycle and the production capacity of the machine tool; determine the direction and magnitude of process parameter adjustment based on the simulation results of tooth surface deviation.

[0015] 8) Conduct gear generating grinding experiments to verify that the produced gears meet the quality inspection requirements such as Fourier transform test and production cycle time.

[0016] As a preferred embodiment of the present invention, the sensitive frequency f is obtained based on historical processing data. ii (ii=1,2,3,…Nii), based on the Fourier transform test, the sensitive frequencies are divided into target frequencies and boundary frequencies to determine the target and boundary conditions for adjusting the process parameters; based on the production cycle requirements and the conditions of the processing equipment itself, the range of process parameter adjustment is determined.

[0017] As a preferred embodiment of the present invention, the process parameter adjustment direction is set to l. mn (m = 1, 2, 3, ..., N) m N m The number of process parameters; n=1 represents an increase in the process parameter, and n=2 represents a decrease in the process parameter; based on the tooth surface deviation simulation model, in a unit adjustment amount δv w , δ△ n and δv wzUnder different adjustment directions, the rate of change kf of the sensitive frequency amplitude is quantitatively calculated. i-mn This allows for a quantitative determination of the direction of adjustment for processing parameters.

[0018] The technical effect of this invention is that it solves the problems of low adjustment efficiency and lack of direction in the trial-and-error method of adjusting process parameters when Fourier detection fails in mass production. It can find the direction of generating grinding process parameter control, improve the efficiency of gear mass production, and reduce production costs. Attached Figure Description

[0019] Figure 1 A flowchart of a method for directional control of gear generating grinding process parameters to address tooth surface deviations;

[0020] Figure 2 A schematic diagram of gear generating grinding;

[0021] Figure 3 This is a schematic diagram showing the direction of process parameter adjustment.

[0022] Figure 4 This is a schematic diagram of process parameter adjustment.

[0023] In the diagram, 1-gear; 2-grinding wheel; 3-process parameter adjustment range. Detailed Implementation

[0024] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0025] A method for directional control of gear generating grinding process parameters to address tooth surface deviations, the process flow of which is as follows: Figure 1 As shown, it includes the following steps:

[0026] Taking the generating grinding of a certain type of gear produced in mass production as an example, such as Figure 2 As shown, grinding wheel 1 is a worm grinding wheel, and gear 2 is the workpiece being machined. During conventional machining, the gear's process parameters remain stable. However, if the Fourier transform test results of a randomly selected gear fail to meet the standards, the machine needs to be stopped, and the grinding process adjusted until the gear's Fourier transform test results meet the standards. Assume only the linear velocity v is adjusted. w Feed rate △ n and feed rate v wz The three process parameters and specific steps are as follows.

[0027] The first step is to collect sensitive frequencies. For this machine tool, historical data on Fourier transform test results for this type of gear are collected, such as... Figure 3 As shown, all anomalous frequencies appearing in the Fourier spectrum are recorded. All anomalous frequencies appearing in the historical data are used as the sensitive frequencies f for machining this type of gear on this machine tool. ii(ii = 1, 2, 3, ... N) ii It is worth noting that it is necessary to distinguish between the sensitive frequencies belonging to the left / right tooth surface and the tooth profile / tooth direction spectrum, and record them separately.

[0028] The second step is to determine the target frequency and boundary frequency within the sensitive frequency range. When encountering anomalies in the Fourier results of the sampled gears, the abnormal frequency is taken as the target frequency f. A1 f A2 f A3 ..., other sensitive frequencies in the historical data are used as boundary frequencies f B1 f B2 f B3 ..., and record the target frequency amplitude (F) at this time. A1 F A2 F A3 ...) and boundary frequency amplitude (F B1 F B2 F B3 It is worth noting that if there is an abnormal frequency that is not among the sensitive frequencies in the historical data, the abnormal frequency should be added to the historical data as a sensitive frequency.

[0029] The third step is to determine the adjustment target and adjustment boundary. Based on the gear Fourier transform testing requirements, calculate the current amplitude (F) of each target frequency. A1 F A2 F A3 The minimum rate of change that needs to be adjusted (a) A1 a A2 a A3 ...), as the adjustment target for generating grinding process parameters; calculate the amplitude of each boundary frequency (F...). B1 F B2 F B3 The maximum adjustable rate of change (A) is... A1 A A2 A A3 ...), which serve as the adjustment boundaries for generating grinding process parameters.

[0030] The fourth step is to list the minimum range and direction of process parameter adjustments. Based on the currently used gear generating and finishing process parameters, and considering the general setting range and adjustment range of each parameter, list the possible directions for process parameter adjustments. For example, the currently used process parameter is Σ0, i.e., the linear velocity v w0 Feed rate n0 and feed rate v wz0 Based on engineering experience, the linear velocity v can be determined. w Feed rate △ n and feed rate v wz The minimum adjustable amplitude is δv. w, δ△ n and δv wz .like Figure 3 As shown, if a single process parameter is adjusted by a unit increment, there are a total of 6 adjustment directions for the process parameter. mn (m = 1, 2, 3; n = 1, 2). If the adjustment is made only in one direction each time, with an adjustment increment of one unit, 6 sets of process parameters are obtained, with each adjustment direction l... mn Corresponding to process parameters Σ mn .

[0031] The fifth step is to establish a simulation model for the deviation of the gear surface in generating grinding. Considering the shape, size, and distribution of abrasive grains on the worm wheel, the model is constructed using process parameters Σ0 and Σ... mn Using this as input, a set of simulation models of the tooth surface morphology of generating grinding were established, and the tooth surface deviation and corresponding Fourier spectra were extracted respectively.

[0032] Step 6: Calculate the rate of change of amplitude of the target frequency and boundary frequency under different adjustment directions. Compare the process parameters Σ of each group. mn The Fourier spectrum relative to the initial process parameter Σ0 is used to calculate the rate of change of the amplitude of the sensitive frequency with respect to the process parameter under a unit adjustment, which is kf. ii-mn .

[0033] Step 7: Determine the adjustment range, direction, and magnitude of the process parameters. For example... Figure 4 As shown, the adjustment direction for each process parameter is determined as l 1i l 2j and l 3k The adjustment ranges are respectively the adjustment range δv in the corresponding unit adjustment direction. w , δ△ n and δv wz If the value is multiples of n1, n2, and n3, then the sensitive frequency f is at this time. ii The rate of change of amplitude is n1*kf ii-1i +n2*kf ii-2j +n3*kf ii-3k Based on the production cycle time and the machine tool's production capacity, determine as follows: Figure 4 The gray hexagon indicates the range of process parameters to be selected. Within this range, a new set of process parameters is randomly selected as the optimized process parameters Σ. The adjustment direction and magnitude of each process parameter are determined, and the target frequency amplitude (F) is checked. A1 F A2 F A3 ...) and boundary frequency amplitude (F B1 F B2 F B3 (...) respectively meet the quality inspection requirements. If the requirements are met, proceed to the next step; if the requirements are not met, reselect the process parameters.

[0034] Step 8: Conduct a gear generating grinding experiment for verification. Grinding is performed according to the optimized process parameters Σ, and the gear Fourier transform is tested to determine if it meets the Fourier transform requirements. If the Fourier transform test, production cycle time, and other quality inspection requirements are met, gear mass production is carried out using process parameters Σ; if the requirements are not met, return to the previous step.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for directional control of gear generating grinding process parameters oriented towards tooth surface deviation, characterized in that, The method includes the following steps: 1) Collect sensitive frequencies: Based on historical processing data, collect abnormal frequencies from the gear Fourier test results and use these abnormal frequencies as sensitive frequencies. 2) Determine the target frequency and boundary frequency within the sensitive frequency range; 3) Determine the adjustment objectives and boundaries; 4) List the minimum range and direction of process parameter adjustments; 5) Establish a simulation model for the deviation of the gear surface during generating grinding; 6) Calculate the rate of change of the amplitude of the target frequency and the boundary frequency under different adjustment directions; 7) Determine the adjustment range, direction, and magnitude of the process parameters; 8) Conduct gear generating grinding experiments to verify the process.

2. The method for directional control of gear generating grinding process parameters oriented towards tooth surface deviation according to claim 1, characterized in that, Based on historical processing data, the sensitive frequency f is obtained. ii , ii=1, 2, 3, …Nii, according to Fourier detection, the sensitive frequencies are divided into target frequencies and boundary frequencies to determine the target and boundary conditions for process parameter adjustment; according to the production cycle requirements and the conditions of the processing equipment itself, the adjustment range of process parameters is determined.

3. The method for directional control of gear generating grinding process parameters oriented towards tooth surface deviation according to claim 1, characterized in that, The direction of process parameter adjustment is set as follows l mn m=1, 2, 3, …, N m N m This represents the number of process parameters; n=1 indicates that the process parameter increases, and n=2 indicates that the process parameter decreases. Based on the tooth surface deviation simulation model, with a unit adjustment amount δv w , δ△ n and δv wz Under different adjustment directions, the rate of change kf of the sensitive frequency amplitude is quantitatively calculated. i-mn This allows for quantitative judgment of the direction of adjustment of processing parameters, where v w Let Δ be the linear velocity. n For feed rate, v wz This is the feed rate.

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