Tooth aligning tool and method for linear cutting machining of internal and external tooth parts

Abstract

The invention belongs to the field of gear manufacturing, and relates to a tooth alignment tool and method for linear cutting machining of internal and external tooth parts, the tool comprises a positioning base and a puller screw, the positioning base is designed to be of a hollow annular structure, and radial and axial positioning of the parts is achieved; and the top of the jacking screw is spherical and is used for jacking the tooth groove without damaging the tooth surface. The method comprises the steps of leveling the positioning base, placing and positioning the part, aligning, jacking the screw, linearly cutting and machining the inner teeth and the like. The method is suitable for parts with straight teeth, helical teeth, odd teeth and even teeth, and has wide applicability; the machining efficiency can be improved, the consistency of parts is guaranteed, and personal errors are reduced; and in addition, batch machining, dismounting and mounting are facilitated, and the durability and the precision retentivity of the tool are improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of gear manufacturing, and relates to a tooth aligning tool and method for line cutting of inner and outer tooth type parts. BACKGROUND

[0002] In the field of mechanical manufacturing, gears are key components for power transmission and motion transmission, and their machining precision and performance directly affect the running efficiency and stability of the entire mechanical system. In particular, in some application scenarios with extremely high requirements for transmission precision and connection reliability, such as aerospace, precision instruments, robots, etc., the machining quality of gears is particularly important. Among them, gears with inner and outer tooth structures are widely concerned due to their ability to meet complex transmission requirements.

[0003] I. Machining requirements of inner and outer tooth type parts

[0004] Inner and outer tooth type parts, as the name implies, refer to gears with both inner and outer tooth structures. In design, in order to meet specific transmission requirements, there are strict requirements on the phase relationship between the inner tooth and the outer tooth. For example, in some transmission systems, it is required that the inner tooth groove and the outer tooth groove must be aligned, with a phase difference of no more than a very small angle (such as 4'), to ensure the stability and accuracy of transmission. This strict phase requirement poses a high challenge to the machining process of gears.

[0005] II. Limitations of traditional machining methods

[0006] For the machining of inner and outer tooth type parts, the traditional method mainly relies on the use of measuring rods for alignment. Specifically, a measuring rod with an appropriate diameter is placed in each of the 180° direction tooth grooves of the outer tooth, and then the high points of the two measuring rods are straightened by the alignment device and ensured to be on the same horizontal plane, thereby ensuring that the two outer tooth grooves are on the same horizontal straight line. However, this method has many limitations in practical application:

[0007] Tooth shape limitation: The traditional method is mainly applicable to the machining of gears with straight teeth. For helical gears, since the tooth direction of the helical gear is at a certain angle with the gear axis, the measuring rod cannot be stably placed in the tooth groove, making it difficult to achieve accurate alignment.

[0008] Tooth number limitation: The traditional method requires that the number of teeth of the outer tooth must be even. This is because only in the case of even teeth, the two measuring rods can be placed in the 180° direction of the part symmetry, thereby achieving straightening and alignment. However, in actual design, odd-numbered gears also exist widely, which makes the traditional method unable to be applied in these situations.

[0009] Low processing efficiency: The traditional method needs repeated adjustment and measurement during the alignment process to ensure that the two gauges are at the same level and straight. This process not only consumes time and effort, but also introduces human error, resulting in low processing efficiency. Especially in batch processing, the cumulative effect of alignment time is more significant, which seriously affects the production efficiency.

[0010] Limited accuracy: Since the traditional method relies on the placement of the gauge and the accuracy of the alignment device, its processing accuracy is limited. Especially when dealing with high-precision gears, the traditional method often fails to meet the design requirements.

[0011] III. Application of wire cutting processing technology

[0012] With the continuous development of manufacturing technology, wire cutting processing technology has been widely used in the field of gear processing due to its high precision and high efficiency. Wire cutting processing removes material through pulse discharge between the electrode wire and the workpiece, thereby realizing the processing of parts. This processing method is not limited by tooth shape and tooth number, and can flexibly cope with various complex gear structures. However, when wire cutting processing internal and external tooth parts, how to achieve accurate control of the teeth becomes a problem to be solved.

[0013] IV. Research and development needs of tooth alignment tool and method

[0014] In view of the limitations of traditional processing methods in wire cutting processing internal and external tooth parts, it is particularly important to develop a new type of tooth alignment tool and method. This new tool and method should be able to break through the limitations of tooth shape and tooth number, achieve accurate control of the teeth, and at the same time, have the characteristics of high efficiency, stability and reliability to meet the needs of batch processing. SUMMARY

[0015] Therefore, the purpose of the present application is to provide a tooth alignment tool and method for wire cutting processing of internal and external tooth parts to solve the existing problems and promote the progress of gear processing technology.

[0016] To achieve the above purpose, the present application provides the following technical solution: a tooth alignment tool for wire cutting processing of internal and external tooth parts, comprising a positioning base and a tightening screw, the positioning base is designed as a hollow ring structure, the hollow part is designed as a stepped hole with large diameter at the top and small diameter at the bottom, the upper large diameter section is used for radial positioning of the outer circle of the part to be processed, and forms a 0.005-0.01mm assembly gap with the outer circle of the part; the top of the lower small diameter section forms an axial positioning step surface, which is used to limit the axial installation position of the part to be processed; the bottom of the positioning base is processed into a straight edge, a through threaded hole is provided in the middle position of the straight edge, and the axis is directed to the stepped hole; the tightening screw cooperates with the threaded hole, and the top of the tightening screw is a spherical structure, which is used to tighten the tooth groove of the external tooth of the part to be processed.

[0017] Optionally, the top screw is made of copper material, and the curvature radius of the spherical top is smaller than the minimum curvature radius of the outer tooth groove.

[0018] Optionally, the positioning base is made of 40Cr alloy steel, and the inner surface of the stepped hole is quenched to have a hardness of ≥45HRC.

[0019] Optionally, the positioning base is designed to have structural dimensions, including an axial positioning depth dimension H1 for limiting the distance from the end face of the part to be machined to the end face of the positioning base, a thread center height dimension H2 for determining the installation height of the top screw, a thread center eccentricity dimension H3 for compensating for the phase deviation of the helical tooth, and a radial positioning diameter dimension H4 for processing with the outer circle of the part to be machined, with a side gap of 0.005-0.01mm.

[0020] A tooth aligning method for internal and external tooth parts machined by wire cutting, which applies the tooth aligning tooling for internal and external tooth parts machined by wire cutting as described above, and comprises the following steps:

[0021] S1, placing the positioning base on the wire cutting machine tool, straightening and leveling by the straight edge at the bottom;

[0022] S2, placing the part to be machined into the positioning base:

[0023] S21, radial positioning by the radial positioning diameter dimension H4;

[0024] S22, axial positioning by the axial positioning depth dimension H1;

[0025] S3, aligning the part to be machined;

[0026] S4, screwing in the top screw to tighten the outer tooth groove, so as to avoid damaging the tooth surface;

[0027] S5, wire cutting machining of the internal tooth, so that the phase deviation between the internal tooth and the external tooth is ≤4′.

[0028] Optionally, in step S2, if the external tooth is a helical tooth, the axial positioning depth dimension H1 determines the values of the thread center height dimension H2 and the thread center eccentricity dimension H3.

[0029] Optionally, in step S2, when the external tooth of the part to be machined is a straight tooth, the thread center eccentricity dimension H3=0.

[0030] Optionally, in step S4, the spherical top of the top screw is in contact with the outer tooth groove.

[0031] Optionally, after step S5, the top screw is unscrewed, and the part is disassembled by using the side gap of the radial positioning diameter dimension H4, and the positioning base does not need to be re-leveled during batch machining.

[0032] The beneficial effects of the present application are:

[0033] 1. Broad applicability

[0034] The tooth matching tool and method designed in this patent is applicable to various parts that require internal and external tooth matching, regardless of whether the external teeth are straight or helical, or whether the number of external teeth is odd or even. It can achieve high-precision tooth matching processing. This feature greatly broadens the application range of the tool and method, making it able to meet the gear processing needs of different fields and different design requirements.

[0035] 2. Improve processing efficiency

[0036] Traditional processing methods require repeated adjustment and measurement during alignment, which is time-consuming, labor-intensive, and inefficient. However, the tooth matching tool and method used in this patent achieves rapid and accurate clamping and alignment by positioning the external gear tooth circle and any end surface of the part, and using custom screws to limit the external gear tooth groove. In batch processing, this tool and method can significantly reduce the alignment and straightening time, thereby improving overall processing efficiency.

[0037] 3. Ensure part consistency

[0038] The tooth matching tool and method of this patent can ensure that each part achieves the precise phase relationship between internal and external teeth in the same section during processing. This is particularly important for gears that require high-precision transmission, as it can avoid transmission errors and vibration problems caused by inconsistent phases. By ensuring part consistency, the stability and reliability of gear transmission are improved.

[0039] 4. Reduce human error

[0040] Traditional processing methods are prone to human error during alignment, such as improper placement of the measuring rod and insufficient accuracy of the alignment device. However, the tooth matching tool and method of this patent reduces human intervention through mechanical positioning and limiting devices, thereby reducing the impact of human error on processing accuracy. This helps to improve the processing accuracy and consistency of gears.

[0041] 5. Facilitate batch processing and disassembly

[0042] The tooth matching tool and method of this patent has a significant advantage in batch processing. By unscrewing the jacking screws and using the side gap between the tooth matching clamp and the part, the parts can be easily disassembled without the need to adjust the tooth matching clamp. This feature makes batch processing more efficient and convenient, reducing labor intensity and production costs.

[0043] 6. Improve tool durability and precision retention

[0044] The tooth matching tool base of the patent adopts 40Cr material and is quenched to improve the overall hardness and wear resistance. This helps to prevent size wear caused by repeated disassembly of the processed parts, thereby maintaining the stability of the tooth matching precision. By improving the durability and precision retention of the tool, the service life of the tool is extended, and the frequency and cost of replacing the tool are reduced.

[0045] Other advantages, objects, and features of the present application will be apparent to those skilled in the art from the following specification, in some degree, and in others, from the practice of the present application. The objects and other advantages of the present application can be realized and attained by the below description. BRIEF DESCRIPTION OF DRAWINGS

[0046] In order to make the purposes, technical solutions and advantages of the present application clearer, the preferred detailed description of the present application will be combined with the drawings as follows, wherein:

[0047] Figure 1 The overall installation schematic diagram of the present application

[0048] Figure 2 The left view of the positioning base of the present application;

[0049] Figure 3 The front view of the positioning base of the present application;

[0050] Figure 4 The schematic diagram of the jacking screw of the present application;

[0051] Figure 5 The overall structure front view of the present application;

[0052] Figure 6 The internal section view of the present application;

[0053] Figure 7 The Figure 6 The enlarged view of the middle I.

[0054] Reference signs: positioning base 1, jacking screw 2, processed part 3. DETAILED DESCRIPTION

[0055] The present application will be further described by way of specific embodiments, and the skilled in the art will readily obtain other advantages and purposes from the disclosure of the specification. The present application can also be implemented or applied in other different specific embodiments, and various modifications or changes can be made to the details based on different views and applications without departing from the spirit of the present application. It should be noted that the drawings provided in the following embodiments only illustrate the basic concept of the present application in a schematic manner, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0056] The drawings are only used for exemplary illustration, and the representation is only a schematic diagram, not a physical diagram, and cannot be understood as a limitation on the present application; in order to better illustrate the embodiments of the present application, some components in the drawings may be omitted, enlarged or reduced, and do not represent the actual product size; for those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted.

[0057] The same or similar reference numerals in the drawings of the embodiments of the present application correspond to the same or similar components; in the description of the present application, it should be understood that if the terms "upper", "lower", "left", "right", "front", "back" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore the terms describing the positional relationship in the drawings are only used for exemplary illustration, and cannot be understood as a limitation on the present application, for those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0058] Please refer to Figures 1-7 It is a tooth matching tool and method for wire cutting processing of internal and external tooth parts, which is suitable for processing of various parts requiring internal and external tooth matching, and especially solves the problems of limited tooth shape and tooth number and low processing efficiency in traditional processing methods. The embodiments of the present application will be described in detail below in combination with the drawings and two specific embodiments (straight teeth and helical teeth).

[0059] Example 1: processing of parts with external straight teeth

[0060] Step 1: tool preparation

[0061] Positioning base 1: made of 40Cr alloy steel, hollow ring structure, upper large aperture section radial positioning diameter size H4 matched with outer circle of the part to be processed 3, side gap 0.008mm; lower small aperture section top end forms an axial positioning step surface, axial positioning depth size H1=15mm (determined according to part design requirements).

[0062] Top screw 2: copper material, top spherical curvature radius is less than the minimum curvature radius of the outer tooth groove, thread specification matches the bottom thread hole of the positioning base 1.

[0063] Step 2: Machine leveling

[0064] Place the positioning base 1 on the wire cutting machine workbench, straighten and level by the bottom straight edge (see attached figure 1). Figure 1 The bottom straight edge of the positioning base 1 is parallel to the machine X-axis.

[0065] Step 3: Part clamping

[0066] Radial positioning: place the part to be processed 3 into the positioning base 1, the upper large hole diameter section matches the gap (side gap 0.008mm) with the part outer circle.

[0067] Axial positioning: the part end face tightly abuts the axial positioning step surface (H1=15mm limits the axial position) of the positioning base 1.

[0068] Step 4: Alignment and fixation

[0069] Fine-tune the part 3 position to ensure its axis is aligned with the machine coordinate system.

[0070] Screw in the top screw 2, the spherical top tightens the outer tooth groove (see attached figure 2). Figure 4 The screw spherical surface contacts the groove, avoiding damage to the tooth surface.

[0071] Step 5: Wire cutting processing

[0072] Start the wire cutting machine, process the inner tooth, and ensure the phase difference between the inner tooth and the outer tooth is ≤4'(through machine programming control discharge position).

[0073] Step 6: Disassembly and batch processing

[0074] After processing, unscrew the top screw 2, and easily take out the part 3 using the side gap 0.008mm.

[0075] When batch processing, there is no need to re-level the positioning base 1, directly repeat steps 3-5.

[0076] Example 2: Part processing with outer teeth as helical teeth

[0077] Step 1: Tooling customization

[0078] Positioning base 1: calculate H1, H2, H3 sizes according to helical tooth parameters. For example, helical tooth helix angle β=15°, module m=2, then H2(thread center height)=H1+m·tanβ=15+2·tan15°≈15.54mm; H3(thread center eccentricity)=m / 2=1mm(compensate phase deviation).

[0079] Top screw 2: same as example 1, but the installation height is adjusted according to H2.

[0080] Step 2: Machine leveling

[0081] Same as example 1, the bottom straight edge of the positioning base 1 is leveled (see attached Figure 1 ).

[0082] Step 3: Part clamping

[0083] Radial positioning: the outer circle of the part 3 is 0.01mm apart from the large hole section side gap of the upper part of the positioning base 1.

[0084] Axial positioning: the end face of the part is tightly attached to the axial positioning step surface of the positioning base 1 (H1 = 15mm).

[0085] Helical tooth tooth contact section determination: according to H2 = 15.54mm, the selected outer tooth width midpoint section is the tooth contact reference surface.

[0086] Step 4: Alignment and fixation

[0087] Fine-tune the part 3 so that the selected section's tooth groove is aligned with the top screw 2.

[0088] Screw in the top screw 2, and the spherical top tightens the tooth groove (see attached Figure 4 ).

[0089] Step 5: Wire cutting processing

[0090] Same as example 1, process the internal teeth and control the phase difference ≤4'.

[0091] Step 6: Disassembly and batch processing

[0092] Same as example 1, use the side gap to easily disassemble and assemble the part 3, and there is no need to re-level during batch processing.

[0093] The present application realizes the tooth processing of straight teeth (H3 = 0) and helical teeth (H3 ≠ 0) through the parameterized design of H1, H2, and H3. The single piece clamping time is ≤2 minutes, and the batch processing efficiency is improved by more than 40%. The positioning base 1 has a hardness of ≥45HRC after 40Cr quenching treatment, and the repeated positioning accuracy is ±0.005mm.

[0094] The examples of the present application verify the feasibility and advantages of the tooth processing tool and method in the processing of straight teeth and helical teeth parts, and provide a reliable technical solution for high-precision gear manufacturing.

[0095] Finally, it is to be explained that the above embodiments are only used to illustrate the technical solutions of the present application but not to limit the present application. Although the present application is described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the purpose and scope of the technical solutions, and all should be covered in the scope of the claims of the present application.

Claims

1. A tooth alignment tool for wire cutting of internal and external gear parts, characterized by: It includes a positioning base and a tightening screw. The positioning base is designed as a hollow annular structure. The hollow part is designed as a stepped hole with a larger upper portion and a smaller lower portion. The upper large-diameter section is used to radially locate the outer circle of the part to be processed and forms an assembly gap of 0.005-0.01mm with the outer circle of the part; the top of the lower small-diameter section forms an axial positioning step surface for limiting the axial installation position of the part to be processed; the bottom of the positioning base is processed into a straight edge, and a through threaded hole is opened in the middle of the straight edge, with the axis facing the stepped hole; The tightening screw cooperates with the threaded hole, and the top of the tightening screw is a spherical structure, which is used to tighten the outer tooth groove of the part to be processed.

2. The tooth alignment tool for wire cutting of internal and external tooth parts according to claim 1, characterized in that: The tightening screw is made of copper, and the curvature radius of the top of the sphere is smaller than the minimum curvature radius of the outer tooth groove.

3. The tooth alignment tool for wire cutting of internal and external tooth parts according to claim 1, characterized in that: The positioning base is made of 40Cr alloy steel, and the inner surface of the stepped hole is quenched to a hardness of ≥45HRC.

4. The tooth alignment tool for wire cutting of internal and external tooth parts according to claim 1, characterized in that: The positioning base is designed with structural dimensions, including the axial positioning depth dimension H1, which limits the distance from the end face of the part to be processed to the end face of the positioning base; the thread center height dimension H2, which determines the installation height of the tightening screw; the thread center eccentricity dimension H3, which is used to compensate for the phase deviation of the helical teeth; and the radial positioning diameter dimension H4, which is matched with the outer circle of the part to be processed and has a side clearance of 0.005-0.01mm.

5. A method for aligning internal and external tooth parts by wire cutting, using a tool for aligning internal and external tooth parts by wire cutting as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: S1, place the positioning base on the wire cutting machine, straighten it and level it by straightening the straight edge at the bottom; S2, place the workpiece to be processed into the positioning base: S21, radial positioning by radial positioning diameter size H4; S22, axial positioning by axial positioning depth dimension H1; S3, align the parts to be processed; S4, screw in the tightening screw to tighten the outer tooth groove to avoid damaging the tooth surface; S5, wire cutting the inner teeth to make the phase difference between the inner teeth and the outer teeth ≤4'.

6. The method for aligning internal and external gear parts by wire cutting according to claim 5, characterized in that: In step S2, if the external teeth are helical teeth, the axial positioning depth dimension H1 determines the values ​​of the thread center height dimension H2 and the thread center eccentricity dimension H3.

7. The method for aligning internal and external tooth parts by wire cutting according to claim 5, characterized in that: In step S2, when the external teeth of the part to be processed are straight teeth, the thread center eccentricity dimension H3=0.

8. The method for aligning internal and external gear parts by wire cutting according to claim 5, characterized in that: In step S4, the top of the ball of the tightening screw contacts the tooth groove of the external tooth.

9. The method for aligning internal and external gear parts by wire cutting according to claim 5, characterized in that: After step S5, the tightening screw is unscrewed and the parts are disassembled using the side clearance of the radial positioning diameter size H4. There is no need to re-level the positioning base during batch processing.

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