Cross-tooth gear milling machining method for gear ring of main bearing of heading machine

Abstract

The invention relates to the technical field of main bearing gear ring machining, in particular to a heading machine main bearing gear ring cross-tooth gear milling machining method which comprises the steps that S1, a gear ring is installed on a rotating table, and the rotating table is used for driving the gear ring to conduct forward and reverse rotation motion and indexing motion; s2, numbering tooth grooves in the gear ring in sequence according to the machining rotation direction, wherein the number of the tooth grooves is a natural number from 1 to Z; s3, the number N of cross teeth is determined, the machining sequence number of tooth grooves is (K-1) N + 1, K is equal to 1, 2,..., Z, the machining sequence numbers of the tooth grooves are sequentially determined according to the sequence of K from 1 to Z, and the machining movement track of the gear milling cutter head is determined based on the tooth groove numbers corresponding to the machining sequence codes; and S4, cross-tooth gear milling machining is conducted on the gear ring based on the machining movement track. By means of the method, the problems of tooth pitch accumulated deviation and pitch circle run-out in the machining process of an existing ultra-large-diameter gear ring are solved, and the rotation precision and the product quality of a main bearing are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of main bearing gear ring processing, and specifically relates to a method for machining a main bearing gear ring of a roadheader by cross-tooth milling. Background Art

[0002] As a core component of the main bearing, the gear ring directly affects the bearing capacity and running stability of the bearing. During the gear milling process of the workpiece, the milling cutter head on the milling machine milling bed makes a circular rotational motion, and the rotary table drives the gear ring to make a circular rotational motion. Through the coordinated rotation of the milling cutter head and the rotary table, the gear milling of each tooth of the gear ring is jointly achieved.

[0003] At present, for large-diameter and large-module gear rings, the workpiece is machined by a milling machine. After soft milling and hard milling, a finished gear ring is obtained. The milling accuracy directly affects the machining accuracy of the gear teeth of the gear ring and the product quality. During the gear milling process, according to the rotation mode of the rotary table, the gear milling methods of the gear ring can be divided into equal-division milling method, sequential milling method, and left and right side sequential milling method; among them, the most commonly used is the equal-division milling method, and the commonly used ones are equal 8-division or equal 16-division. However, when milling a gear ring with a diameter of more than 6m, due to the certain coupling clearance in the transmission of the two sets of worm and worm gear mechanisms that drive the rotary table of the milling machine to rotate, when the traditional equal-division milling method is used for a gear ring with too many teeth, it causes the rotary table to rotate too many circles to complete the entire gear milling process of the gear ring. If the rotary table of the milling machine rotates too many circles, it will cause the cumulative error of the coupling clearance of the worm and worm gear mechanism to be too large, and further affect the tooth division angle error between the teeth of the gear ring by the rotary table to be too large, resulting in too large cumulative deviation of tooth pitch and tooth pitch circle runout of the finished gear ring, and ultimately affecting the product accuracy and service performance of the gear ring.

[0004] In summary, there is an urgent need for a method for machining a main bearing gear ring of a roadheader by cross-tooth milling to solve the problems in the prior art. Summary of the Invention

[0005] The purpose of the present invention is to provide a method for machining a main bearing gear ring of a roadheader by cross-tooth milling, which is used to optimize the cumulative deviation of tooth pitch and tooth pitch circle runout during the gear ring machining process. The specific technical solution is as follows:

[0006] A method for machining a main bearing gear ring of a roadheader by cross-tooth milling includes the following steps:

[0007] S1: Install the gear ring on the rotary table, and the rotary table is used to drive the gear ring to perform forward and reverse rotation and indexing movement;

[0008] S2: Number each tooth groove on the gear ring in sequence according to the processing rotation direction, and the tooth groove numbers are natural numbers from 1 to Z;

[0009] S3: Determine the number of teeth across N. The machining sequence number of the tooth space is (K - 1)N + 1, where K = 1, 2, …, Z. Determine the machining sequence number of the tooth spaces in the order of K from 1 to Z, and determine the machining movement trajectory of the gear milling cutter head based on the tooth space number corresponding to the machining sequence code.

[0010] S4: Perform across - tooth gear milling on the gear ring based on the machining movement trajectory.

[0011] Optionally, in S1, the gear ring is detachably arranged on the rotary workbench through a gear milling bracket and a gear milling faceplate.

[0012] Optionally, in S1, the rotary workbench realizes forward and reverse rotation movements and indexing movements through two sets of turbine screw mechanisms.

[0013] Optionally, in S3, the value of Z / N is an infinite decimal.

[0014] Optionally, in S3, optimize and adjust the number of teeth across N according to the milling iron chip state of the gear ring, the vibration condition of the workpiece, and the machining quality of the tooth space surface.

[0015] Optionally, in S4, the determination method of the tooth space code for machining the tooth spaces in the machining movement trajectory is as follows:

[0016] When (K - 1)N + 1 ≤ Z, the tooth space number is taken as (K - 1)N + 1;

[0017] When (K - 1)N + 1 > Z, the tooth space number is taken as (K - 1)N + 1 - {Math.floor[(K - 1)N + 1] / Z}×Z, where Math.floor means discarding the digits after the decimal point of the quotient and taking the integer; and when the calculation result of the tooth space number is 0, the tooth space number is taken as Z, where K = 1, 2, …, Z, and K takes values in ascending order.

[0018] Optionally, in S4, in the across - tooth gear milling process, first machine the first cut for all tooth spaces according to the machining movement trajectory, and then repeat the remaining machining cuts according to the machining movement trajectory until the gear milling of the entire gear ring is completed.

[0019] Optionally, in S4, the across - tooth gear milling includes soft gear milling and hard gear milling performed in sequence.

[0020] Applying the technical solution of the present invention has the following beneficial effects:

[0021] The present invention provides a method for machining the tooth ring of a main bearing of a roadheader by cross-tooth milling, which solves the problem that it is difficult to control the machining accuracy of the tooth ring with an ultra-large diameter, and effectively ensures the production accuracy of the finished teeth of the tooth ring with a large diameter and large module. The method of the present invention improves the rotational accuracy of the teeth of the tooth ring through the cross-tooth machining method, improves the stress condition of the teeth of the tooth ring, and improves the product quality and service life of the bearing. By applying the method for machining the tooth ring with an ultra-large diameter and ultra-large module proposed by the present invention, it is possible to avoid the large cumulative error of the indexing angle of the tooth ring milling caused by the poor indexing accuracy of the rotary table of the tooth milling machine due to the large diameter of the workpiece, and further optimize the cumulative pitch deviation and pitch circle runout of the gear teeth, and improve the rotational accuracy and product quality of the main bearing.

[0022] In addition to the purposes, features and advantages described above, the present invention has other purposes, features and advantages. The present invention will be further described in detail below with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0024] Figure 1 It is a flowchart of the steps of the method for machining the tooth ring of the main bearing of the roadheader in the preferred embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] In order to enable those skilled in the art to better understand the solution of the present invention, the present invention will be further described in detail below with reference to the drawings and specific embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0026] The processing route of the tooth ring mainly consists of rough turning, raceway quenching, semi-finish turning, soft tooth milling, tooth quenching, finish turning, drilling, hard tooth milling and grinding processes; in the tooth milling process, the workpiece is first placed on the tooth milling bracket, and the circumference of the workpiece is tapped with a copper bar. After the workpiece is aligned and vibrated round, the workpiece is fixed and limited by a fixture.

[0027] As Figure 1 shown, this embodiment provides a method for machining the tooth ring of the main bearing of the roadheader by cross-tooth milling, including the following steps:

[0028] S1: Install the gear ring on the rotary table, which is used to drive the gear ring to perform forward and reverse movements and indexing movements.

[0029] Specifically, in this embodiment, the gear ring is detachably arranged on the rotary table through a milling tooth bracket and a milling tooth chuck. In this embodiment, the gear ring and the milling tooth bracket are connected by a T-shaped nut, a pressing plate and a screw rod. The milling tooth bracket and the milling tooth chuck are connected by screws. The rotary table realizes forward and reverse movements and indexing movements through two sets of turbine screw mechanisms.

[0030] S2: Number each tooth groove on the gear ring in sequence according to the processing rotation direction. The tooth groove numbers are natural numbers from 1 to Z. It should be noted that Z is also the total number of teeth of the gear ring at the same time.

[0031] S3: Determine the number of teeth across N. The processing sequence number of the tooth groove is (K - 1)N + 1, where K = 1, 2,..., Z. Determine the processing sequence number of the tooth groove in the order of K from 1 to Z, and determine the processing movement trajectory of the milling cutter head based on the tooth groove number corresponding to the processing sequence code.

[0032] Specifically, the value of the number of teeth across N in this embodiment needs to satisfy that the value of Z / N is an infinite decimal and N ≥ 5. The value range of the number of teeth across N in this embodiment is preferably from 5 to 10. It should be noted that at this time, for the number of teeth across N, through the above calculation, the processing sequence number of the tooth groove is unique, and the processing sequence number does not repeat from 1 to the number of teeth Z.

[0033] Furthermore, the way to obtain the number of teeth across N is as follows:

[0034] If the number of teeth (tooth groove number) of the gear ring is Z, the value range of N can be 5 ≤ N ≤ Z / 12, and it is necessary to satisfy that Z / N is an infinite decimal; all N values that meet the above requirements are qualified. In this embodiment, the process of milling across teeth can be optimized by adjusting the value of N. In this embodiment, the value of N can be fluctuated and selected within the satisfied range, and it can be adjusted according to the pitch circle runout and the total cumulative pitch deviation of the teeth processed in the first few cuts of rough milling teeth, and the optimal one is selected (the best number of teeth across is obtained by soft milling teeth, and it can be directly applied in the last few cuts of soft milling teeth and hard milling teeth).

[0035] It should be noted that the value of the number of teeth across needs to be as small as possible on the premise of meeting the pitch circle runout and the total cumulative pitch deviation of the teeth, so that the number of rotations of the gear ring is less during the entire milling tooth processing, and the cumulative rotation deviation of the rotary table is smaller. Since too small a number of teeth across will cause the release of milling tooth stress and cause the deformation of the gear teeth, the number of teeth across N should not be less than 5. In this embodiment, the gear ring of the main bearing is processed, and the range of 5 to 10 for the number of teeth across is the best. The specific N can be adjusted according to the pitch circle runout and the total cumulative pitch deviation of the teeth processed in the first few cuts of rough milling teeth.

[0036] Further, in this embodiment, the number of teeth across which the milling is performed, N, is also optimized and adjusted according to the state of the milling chips of the gear ring, the vibration of the workpiece, and the machining quality of the tooth groove surface. The adjustment methods include at least one of the following:

[0037] When the number of teeth across which the milling is performed, N, of the workpiece is relatively large, and there are irregular vibration marks on the milling chips during the gear milling process, the workpiece vibrates unevenly or irregularly during the feeding process, and there are wavy milling marks on the surface of the teeth, it is necessary to appropriately reduce the number of teeth across which the milling is performed, N.

[0038] When N is relatively small during the gear milling process, the release of the milling cutting stress during the gear milling process causes deformation of the teeth, ultimately resulting in out-of-tolerance pitch circle runout and cumulative pitch deviation of the teeth. At this time, after the gear ring is machined by gear milling, the pitch circle of the gear ring shows a "steamed roll-shaped" fluctuation. At this time, it is necessary to increase the number of teeth across which the milling is performed, N, within the value range.

[0039] S4: Perform gear milling across teeth on the gear ring based on the machining motion trajectory.

[0040] Specifically, in S4, the method for determining the tooth groove code of the machined tooth groove in the machining motion trajectory is as follows:

[0041] When (K - 1)N + 1 ≤ Z, the tooth groove number is taken as (K - 1)N + 1;

[0042] When (K - 1)N + 1 > Z, the tooth groove number is taken as (K - 1)N + 1 - {Math.floor[(K - 1)N + 1] / Z} × Z, where Math.floor represents discarding the decimal part of the quotient and taking the integer; and when the calculation result of the tooth groove number is 0, the tooth groove number is taken as Z, where K = 1, 2,..., Z, and K takes values in ascending order.

[0043] Optionally, in S4, in the gear milling across teeth, all tooth grooves are first machined for the first cut according to the machining motion trajectory, and then the remaining machining cuts are repeated according to the machining motion trajectory until the gear milling of the entire gear ring is completed.

[0044] Optionally, in S4, the gear milling across teeth includes soft gear milling and hard gear milling performed in sequence.

[0045] It should be noted that the device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place, or may be distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0046] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for machining the teeth of the main bearing gear ring of a roadheader by cross-tooth milling, characterized in that, It includes the following steps: S1: Mount the gear ring on the rotary workbench, which is used to drive the gear ring to perform forward and reverse motions and indexing motions; S2: Number each tooth groove on the gear ring in sequence according to the processing rotation direction, and the tooth groove numbers are natural numbers from 1 to Z; S3: Determine the number of teeth across N. The processing sequence number of the tooth groove is (K - 1)N + 1, where K = 1, 2,..., Z. Determine the processing sequence number of the tooth groove in the order of K from 1 to Z, and determine the machining motion trajectory of the gear milling cutter head based on the tooth groove number corresponding to the processing sequence code; S4: Perform gear milling across teeth on the gear ring based on the machining motion trajectory.

2. The method for machining the cross-tooth of the ring gear of the main bearing of a roadheader according to claim 1, wherein, In S1, the gear ring is detachably arranged on the rotary workbench through a gear milling bracket and a gear milling faceplate.

3. The method for machining the tooth ring of the main bearing of a roadheader by cross-tooth milling according to claim 1, characterized in that, In S1, the rotary workbench realizes forward and reverse motions and indexing motions through two sets of worm and screw mechanisms.

4. The milling method for the cross teeth of the main bearing gear ring of the roadheader according to claim 1, characterized in that In S3, it is satisfied that the value of Z / N is an infinite decimal.

5. The milling method for the cross teeth of the main bearing gear ring of the roadheader according to claim 1, characterized in that In S3, optimize and adjust the number of teeth across N according to the chip state of the gear ring during gear milling, the vibration condition of the workpiece, and the machining quality of the tooth groove surface.

6. The method for machining the cross-tooth of the ring gear of the main bearing of a roadheader according to claim 1, characterized in that In S4, the determination method of the tooth groove code for machining the tooth groove in the machining motion trajectory is as follows: When (K - 1)N + 1 ≤ Z, the tooth groove number takes (K - 1)N + 1; When (K - 1)N + 1 > Z, the tooth groove number takes (K - 1)N + 1 - {Math.floor[(K - 1)N + 1] / Z} × Z, where Math.floor means rounding down the quotient after the decimal point and taking the integer; and when the calculation result of the tooth groove number is 0, the tooth groove number takes Z, where K = 1, 2,..., Z, and K takes values in ascending order.

7. The method for machining the cross-tooth of the main bearing gear ring of a roadheader according to claim 1, characterized in that, In S4, in the gear milling across teeth, for all tooth grooves, the first cut is completed according to the machining motion trajectory, and then the remaining machining passes are repeated according to the machining motion trajectory until the gear milling of the entire gear ring is completed.

8. The tooth milling method for the ring gear of the main bearing of a roadheader according to claim 1, characterized in that, In S4, the gear milling across teeth includes soft gear milling and hard gear milling performed in sequence.

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