A method for machining tooth profiles by honing or shaving.

Abstract

This invention discloses a method for machining the tooth profile of honed or shaved teeth, solving the problems of high difficulty, low feasibility, and inability to ensure a stable and qualified tooth profile in the products after honing or shaving in the existing technology. Specifically, it includes: Step 1, determining the tooth state of the blank tooth to be processed; Step 2, processing the corresponding blank tooth according to the tooth state determination result. This invention refines and classifies the tooth state of the blank tooth, and uses different processing parameters for different tooth states, resulting in high feasibility, improved tooth accuracy and defect rate of the processed product, and the ability to ensure a stable and qualified tooth profile in the honed or shaved product.

Description

Technical Field

[0001] This invention relates to tooth shaving and honing, and more specifically to a method for machining the tooth profile of honing or shaving. Background Technology

[0002] The basic principles of gear shaving and honing are the same, both involving backlash-free transmission between a pair of intersecting gear shafts. Due to inherent limitations in their processing principles, when the overlap ratio is low during gear shaving and honing, the tooth profile of the gear tends to resemble an "S" or "ε" shape. The greater the extrusion deformation force during processing, the greater the deviation from the desired ideal tooth profile, resembling a "|" or "C" shape.

[0003] Currently, the main tooth profile control strategies employed in existing technologies are to improve machining overlap and reduce machining extrusion deformation, while simultaneously combining these with methods to control and improve the accuracy of the blank tooth profile, so that the honing or shaving process is as close to the ideal state as possible. However, due to the numerous uncontrollable and unstable factors affecting the machining process, the tooth profile of the blank cannot be maintained at the ideal state. Figure 1 (a) and Figure 1 The ideal or acceptablely stable state shown in (b) is often in the following condition: Figure 2 (a) and Figure 2 (b) shows an asymmetric state that is unfavorable to honing or shaving processes, and, as Figure 3 As shown, the tooth shape of the blank often changes continuously over time, causing the honing or shaving tools to fail. This makes the tooth shape processing difficult, impractical, and unable to ensure that the product after honing or shaving is in a stable and qualified tooth shape state.

[0004] Chinese invention patent CN103231125B discloses a novel honing method. This invention utilizes a specially designed honing wheel. In the axial plane of the honing wheel, the even-numbered tooth surfaces II on the same side are thinner than the odd-numbered tooth surfaces I. During honing, the overlap between the honing wheel and the gear being processed is less than or equal to 1, ensuring that the cutting force from the tooth tip to the tooth root remains constant when honing each tooth surface. However, its feasibility is still too weak. Summary of the Invention

[0005] In order to solve the technical problems of high difficulty, low feasibility, and inability to ensure that the honed or shaved teeth are in a stable and qualified tooth shape state in the existing technology, the present invention provides a method for honing or shaving teeth.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A method for machining tooth profiles by honing or shaving, characterized by comprising the following steps:

[0008] Step 1: Determine the tooth condition of the blank to be processed, wherein the tooth condition includes:

[0009] A. The total deviation of the tooth profile of the blank tooth to be processed is Fa≤0.015;

[0010] B. The total deviation Fa of the tooth profile of the blank to be processed is greater than 0.015, and the deviation ffa of the tooth profile shape on the left side is... L ≤0.006 and right tooth profile shape deviation ffa R ≤0.006;

[0011] C. The total deviation Fa of the tooth profile of the blank to be processed is greater than 0.015, and the deviation ffa of the tooth profile shape on the left side is greater than 0.015. L And right tooth profile shape deviation ffa R At least one of them is greater than 0.006, and the difference in tooth shape error between the left and right sides is |ffa L -ffa R |≤0.004, and the vertical distance Δr between the concave point in the left tooth profile and the concave point in the right tooth profile in the direction of the radius of the blank tooth to be processed is ≤0.2*H; H is the effective tooth height of the corresponding gear tooth;

[0012] D. The total deviation of the tooth profile of the blank to be processed, Fa, is greater than 0.015; the deviation of the tooth profile shape on the left side is ffa. L And right tooth profile shape deviation ffa R At least one of them is greater than 0.006, and the difference in the left and right tooth shape errors is |ffa L -ffa R |>0.004 or Δr>0.2*H;

[0013] Step 2: Based on the tooth condition assessment results, process the corresponding blank teeth to be processed;

[0014] When the tooth condition of the blank to be machined is A, the machining allowance on one side is set to 0.02 mm to 0.03 mm, the cutting speed is 60 rpm to 80 rpm, the workpiece axial feed rate is 0.3 mm / rpm to 0.4 mm / rpm, and the single radial feed amount is less than 0.02 mm, and the blank tooth with tooth condition A is machined.

[0015] When the tooth condition of the blank to be machined is B, the machining allowance on one side is set to 0.04 mm-0.05 mm, the cutting speed is 60 rpm-80 rpm, the workpiece axial feed rate is 0.3 mm / rpm-0.4 mm / rpm and the single radial feed is less than 0.02 mm, and the blank tooth with tooth condition B is machined.

[0016] When the tooth condition of the blank to be machined is C, the machining allowance on one side is set to 0.04 mm-0.05 mm, the cutting speed is 140 rpm-160 rpm, the workpiece axial feed rate is 0.15 mm / rpm-0.25 mm / rpm, and the single radial feed is 0.02 mm-0.03 mm. The blank tooth with tooth condition C is then machined.

[0017] When the tooth state of the blank to be processed is D, adjust the processing parameters of the previous process to change its state to A, B or C before processing.

[0018] Furthermore, in step 2, when the tooth state of the blank tooth to be processed is A, the machining allowance on one side is set to 0.025 mm.

[0019] Furthermore, in step 2, when the tooth state of the blank to be processed is A, the cutting speed is set to 70 rpm.

[0020] Furthermore, in step 2, when the tooth state of the blank to be processed is A, the axial feed speed of the workpiece is set to 0.35 mm / revolution, and the single radial feed amount is 0.01 mm.

[0021] Furthermore, in step 2, when the tooth state of the blank tooth to be processed is B, the machining allowance on one side is set to 0.045 mm.

[0022] Furthermore, in step 2, when the tooth state of the blank to be processed is B, the cutting speed is set to 70 rpm.

[0023] Furthermore, in step 2, when the tooth state of the blank to be processed is B, the axial feed speed of the workpiece is set to 0.35 mm / revolution, and the single radial feed amount is 0.01 mm.

[0024] Furthermore, in step 2, when the tooth state of the blank tooth to be processed is C, the machining allowance on one side is set to 0.045 mm.

[0025] Furthermore, in step 2, when the tooth state of the blank to be processed is C, the cutting speed is set to 150 rpm.

[0026] Furthermore, in step 2, when the tooth state of the blank to be processed is C, the axial feed speed of the workpiece is set to 0.2 mm / revolution, and the single radial feed amount is 0.03 mm.

[0027] The beneficial effects of this invention are:

[0028] 1. The present invention provides a tooth profile machining method for honing or shaving teeth. After refining and classifying the tooth state of the blank teeth, different machining parameters are used for machining according to different tooth states. This method is highly feasible, improves the tooth accuracy and defect rate of the machined product, and enables the machined product to be in a stable and qualified tooth profile state.

[0029] 2. The tooth profile machining method for honing or shaving provided by the present invention does not require a large investment of costs. In order to achieve better accuracy and yield, the existing technology requires the Fa and ffa errors of the blank teeth to be as small as possible, which greatly increases the investment of equipment, tools, manpower and inspection resources in blank machining.

[0030] 3. The ratio of roughing equipment to shaving and honing equipment for blank teeth on the production line is generally 2:1 or higher. The blank teeth produced by different roughing equipment will inevitably have different tooth conditions, and there will inevitably be asymmetrical tooth shapes such as large differences in left and right FFA and large differences in the concave position. Existing technology cannot effectively deal with this situation. The classification control method proposed in this invention can effectively solve this problem.

[0031] 4. When the tooth is in state A, the machining allowance on one side is reduced by 45% compared with the prior art, which improves the machining efficiency and tool life in this state. Attached Figure Description

[0032] Figure 1 These are blank tooth profiles for honing or shaving, where (a) is a blank tooth profile with symmetrical tooth profiles on the left and right sides, and (b) is a blank tooth profile with approximately symmetrical tooth profiles on the left and right sides.

[0033] Figure 2 These are tooth profile diagrams for honing or shaving teeth, which are unfavorable for machining. Among them, (a) and (b) are tooth profile diagrams with completely asymmetrical tooth profiles on the left and right sides, respectively.

[0034] Figure 3 It is a diagram showing the continuous change of the blank tooth profile over time.

[0035] Figure 4 This is a schematic flowchart of a tooth profile machining method for honing or shaving teeth according to the present invention.

[0036] Figure 5 This is a schematic diagram showing the specific orientation of Δr and H in an embodiment of the present invention. Detailed Implementation

[0037] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] The principles of gear shaving and honing are basically the same, both involving backlash-free transmission of a pair of interlaced gears. When the overlap ratio during machining is less than 1.75, both machining methods exhibit the phenomenon that the post-machining tooth profile is affected by the pre-machining tooth profile accuracy and machining parameters, especially noticeable in gear shaving. Simultaneously, due to various machining factors, both methods can produce varying degrees of machining "mid-concavity." Utilizing this phenomenon and its occurrence patterns, when the blank tooth profile is favorable for machining, a strategy to suppress "mid-concavity" is adopted; when the blank is in a favorable position before honing... Figure 2 and / Figure 3 When faced with unfavorable or unstable conditions, a strategy of amplifying the "concave" phenomenon is adopted to make its machining state under tool-less shaping conditions close to that of the machined state. Figure 1 (b) is an acceptable state, which, combined with reverse compensation of the honing tool, enables the production of a stable product that meets the accuracy requirements after honing.

[0039] This embodiment is based on the above concept, such as Figure 4 As shown, the following post-processing tooth profile control strategy was adopted in the production and processing of shaving and honing:

[0040] Strategy 1: When the tooth profile of the blank is stable before machining, regardless of the tooth profile... Figure 1 (a) shows better accuracy or as Figure 1 (b) When the tooth profile is poor but the left and right shapes are symmetrical, machining parameters such as low allowance, low speed, and low feed are used to suppress the "concave" phenomenon, so that the tooth profile accuracy of the blank before machining becomes the main influencing factor of the accuracy after machining, ensuring that the gear can maintain a stable and good tooth profile accuracy after honing.

[0041] Strategy 2, before processing, such as Figure 2 , Figure 3 When the tooth profile shown is of poor accuracy, asymmetrical, or unstable, a large allowance, high speed, and low feed machining parameters are used to amplify the magnified "central concavity" phenomenon generated by the machining parameters, making it dominant. The resulting "central concavity" tooth profile covers the irregular and unstable tooth profile before machining. At this time, the machining process state changes from unstable to as follows. Figure 1 (b) shows stability. Combined with the reverse compensation design of the honing tool, the machined tooth profile can be kept in a stable and qualified tooth profile accuracy.

[0042] The specific processing steps include:

[0043] Step 1: Determine the tooth condition of the blank. The tooth condition includes:

[0044] A. The total profile deviation Fa of the blank tooth to be processed is ≤0.015; it is not necessary to judge the correlation of FFA and the position of the concave point (the state is symmetrical, the accuracy is good, and it is acceptable).

[0045] B. The total deviation Fa of the tooth profile of the blank to be processed is greater than 0.015, and the deviation ffa of the tooth profile shape on the left side is... L ≤0.006 and right tooth profile shape deviation ffa R ≤0.006; no need to judge the FFA difference and the position of the concave point (the state is symmetrical, the accuracy is poor, but acceptable);

[0046] C. The total deviation Fa of the tooth profile of the blank to be processed is greater than 0.015, and the deviation ffa of the tooth profile shape on the left side is greater than 0.015. L And right tooth profile shape deviation ffa R At least one of them is greater than 0.006, and the difference in tooth shape error between the left and right sides is |ffa L -ffa R |≤0.004, and Δr≤0.2*H; For example Figure 5 As shown, Δr is the vertical distance between the concave point in the left tooth profile and the concave point in the right tooth profile in the direction of the radius of the blank tooth to be processed, and H is the effective tooth height of the corresponding gear tooth; (the state is asymmetrical, the accuracy is poor, but acceptable).

[0047] D. The total deviation of the tooth profile of the blank to be processed, Fa, is greater than 0.015; the deviation of the tooth profile shape on the left side is ffa. L And right tooth profile shape deviation ffa R At least one of them is greater than 0.006, and the difference in the left and right tooth shape errors is |ffa L -ffa R | > 0.004 or Δr > 0.2*H; (The state is asymmetrical, the accuracy is poor, and it is not acceptable);

[0048] Step 2: Based on the tooth condition assessment results, process the corresponding blank teeth to be processed;

[0049] When the tooth condition of the blank to be machined is A, the machining allowance on one side is set to 0.02 mm to 0.03 mm, the cutting speed is 60 rpm to 80 rpm, the workpiece axial feed rate is 0.3 mm / rpm to 0.4 mm / rpm, and the single radial feed is less than 0.02 mm. The blank tooth in tooth condition A is then machined. In this embodiment, a smaller machining allowance on one side and machining parameters that are less likely to produce concavity can be set. Specifically, the machining allowance on one side is 0.025 mm, the cutting speed is 70 rpm, the axial feed rate is 0.35 mm / rpm, and the single radial feed is 0.01 mm.

[0050] When the tooth condition of the blank to be machined is B, the machining allowance on one side is set to 0.04 mm-0.05 mm, the cutting speed is 60 rpm-80 rpm, the workpiece axial feed rate is 0.3 mm / rpm-0.4 mm / rpm, and the single radial feed is less than 0.02 mm. The blank tooth with tooth condition B is then machined. In this embodiment, a larger machining allowance on one side and machining parameters that are less likely to produce concavity can be set. Specifically, the machining allowance on one side is 0.045 mm, the cutting speed is 70 rpm, the axial feed rate is 0.35 mm / rpm, and the single radial feed is 0.01 mm.

[0051] When the tooth condition of the blank to be machined is C, the machining allowance on one side is set to 0.04 mm-0.05 mm, the cutting speed is 140 rpm-160 rpm, the workpiece axial feed rate is 0.15 mm / rpm-0.25 mm / rpm, and the single radial feed is 0.02 mm-0.03 mm. The blank tooth with tooth condition C is then machined. In this embodiment, a larger machining allowance on one side and machining parameters that easily produce concavity can be set. Specifically, the machining allowance on one side is 0.045 mm, the cutting speed is 150 rpm, the axial feed rate is 0.2 mm / rpm, and the single radial feed is 0.03 mm.

[0052] When the tooth condition of the blank to be processed is D, honing or shaving is not allowed. The processing parameters of the previous process need to be improved to change its condition to A, B or C before processing.

[0053] For blank teeth with poor tooth profile accuracy and asymmetry, this embodiment adopts machining parameters that easily produce concave teeth, such as high speed, small axial feed, and large radial feed, so that the tooth profile of the blank teeth after machining becomes a B state with poor accuracy and symmetry, in conjunction with reverse compensation machining of the tool tooth profile.

[0054] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions within the technical scope disclosed in the present invention should be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for machining tooth profiles by honing or shaving, characterized in that, Includes the following steps: Step 1: Determine the tooth condition of the blank to be processed. The tooth condition includes: A. The total deviation of the tooth profile of the blank tooth to be processed is Fa≤0.015; B. The total deviation Fa of the tooth profile of the blank to be processed is greater than 0.015, and the deviation ffa of the tooth profile shape on the left side is... L ≤0.006 and right tooth profile shape deviation ffa R ≤0.006; C. The total deviation Fa of the tooth profile of the blank to be processed is greater than 0.015, and the deviation ffa of the tooth profile shape on the left side is greater than 0.

015. L And right tooth profile shape deviation ffa R At least one of them is greater than 0.006, and the difference in tooth shape error between the left and right sides is |ffa L -ffa R |≤0.004, and the vertical distance Δr between the concave point in the left tooth profile and the concave point in the right tooth profile in the direction of the radius of the blank tooth to be processed is ≤0.2*H; H is the effective tooth height of the corresponding gear tooth; D. The total deviation of the tooth profile of the blank to be processed, Fa, is greater than 0.015; the deviation of the tooth profile shape on the left side is ffa. L And right tooth profile shape deviation ffa R At least one of them is greater than 0.006, and the difference in the left and right tooth shape errors is |ffa L -ffa R |>0.004 or Δr>0.2*H; Step 2: Based on the tooth condition assessment results, process the corresponding blank teeth to be processed; When the tooth condition of the blank to be machined is A, the machining allowance on one side is set to 0.02 mm to 0.03 mm, the cutting speed is 60 rpm to 80 rpm, the workpiece axial feed rate is 0.3 mm / rpm to 0.4 mm / rpm, and the single radial feed amount is less than 0.02 mm, and the blank tooth with tooth condition A is machined. When the tooth condition of the blank to be machined is B, the machining allowance on one side is set to 0.04 mm-0.05 mm, the cutting speed is 60 rpm-80 rpm, the workpiece axial feed rate is 0.3 mm / rpm-0.4 mm / rpm and the single radial feed is less than 0.02 mm, and the blank tooth with tooth condition B is machined. When the tooth condition of the blank to be machined is C, the machining allowance on one side is set to 0.04 mm-0.05 mm, the cutting speed is 140 rpm-160 rpm, the workpiece axial feed rate is 0.15 mm / rpm-0.25 mm / rpm, and the single radial feed is 0.02 mm-0.03 mm. The blank tooth with tooth condition C is then machined. When the tooth state of the blank to be processed is D, adjust the processing parameters of the previous process to change its state to A, B or C before processing.

2. The tooth profile machining method for honing or shaving according to claim 1, characterized in that: In step 2, when the tooth state of the blank to be processed is A, the machining allowance on one side is set to 0.025 mm.

3. The tooth profile machining method for honing or shaving teeth according to claim 2, characterized in that: In step 2, when the tooth state of the blank to be processed is A, the cutting speed is set to 70 rpm.

4. The tooth profile machining method for honing or shaving according to claim 3, characterized in that: In step 2, when the tooth state of the blank to be processed is A, the axial feed speed of the workpiece is set to 0.35 mm / revolution, and the single radial feed amount is 0.01 mm.

5. The tooth profile machining method for honing or shaving according to any one of claims 1-4, characterized in that: In step 2, when the tooth state of the blank to be processed is B, the machining allowance on one side is set to 0.045 mm.

6. The tooth profile machining method for honing or shaving according to claim 5, characterized in that: In step 2, when the tooth state of the blank to be processed is B, the cutting speed is set to 70 rpm.

7. The tooth profile machining method for honing or shaving according to claim 6, characterized in that: In step 2, when the tooth state of the blank to be processed is B, the axial feed speed of the workpiece is set to 0.35 mm / revolution, and the single radial feed amount is 0.01 mm.

8. The tooth profile machining method for honing or shaving according to claim 7, characterized in that: In step 2, when the tooth state of the blank to be processed is C, the machining allowance on one side is set to 0.045 mm.

9. The tooth profile machining method for honing or shaving according to claim 8, characterized in that: In step 2, when the tooth state of the blank to be processed is C, the cutting speed is set to 150 rpm.

10. The tooth profile machining method for honing or shaving according to claim 9, characterized in that: In step 2, when the tooth state of the blank to be processed is C, the axial feed speed of the workpiece is set to 0.2 mm / revolution, and the single radial feed amount is 0.03 mm.

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