Indexable gear hob easy to replace and high in utilization rate

Abstract

The invention relates to the technical field of indexable gear hobs, and discloses an easily-replaced high-utilization-rate indexable gear hob which comprises a hob body, and hob grooves distributed in a circumferential array mode are formed in the hob body; the cutter blade is an indexable cutter blade and is mounted in the cutter groove; the fastening mechanism is used for tightly pressing and fixing the blade in the cutter groove through a pressing force which is inclined to a component in the radial direction of the cutter body; the hobbing cutter has the advantages of high-precision positioning, quick and reliable replacement, stepped reutilization of the blade and efficient utilization of resources, and solves the problems of unstable machining quality and complicated and time-consuming replacement of the blade caused by low positioning precision of a clamping structure of a traditional hobbing cutter, and cutter waste and high cost caused by an integral structure.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of indexable gear hobbing cutter, in particular to an easily replaceable high-usage indexable gear hobbing cutter. BACKGROUND

[0002] As a key tool for efficient gear machining, indexable gear hobbing cutter plays an important role in modern manufacturing industry. Its design of replaceable blade significantly improves the service life and machining efficiency of the tool, especially for rough and finish machining of medium and large modulus gears. Traditional whole hobbing cutter needs repeated grinding, which not only consumes time and effort, but also increases the cost of use. The emergence of indexable structure greatly improves the convenience and economy of on-site operation, meets the development needs of intelligent and green high-end equipment manufacturing, and has important significance for promoting the technological progress and industrial upgrading of tool industry.

[0003] However, the existing indexable gear hobbing cutter still has many limitations. For example, the connection structure of the blade and the tool body often relies on axial screw fastening, which can easily lead to insufficient positioning accuracy, uneven clamping force, and loosening during high-speed cutting, affecting machining accuracy and safety. In addition, traditional blades are not reusable or their sizes cannot be adjusted, causing resource waste and cost increase. Some structural designs do not fully consider the reuse of blades after multiple machining, limiting their economy and environmental friendliness. In contrast, the present application optimizes the blade clamping method, enhances the repeatability of positioning accuracy, realizes the adjustable size and stepwise reuse of blades, effectively overcoming the above defects and improving the overall performance and sustainability. SUMMARY

[0004] (I) The technical problem solved: In view of the deficiencies of the prior art, the present application provides an easily replaceable high-usage indexable gear hobbing cutter, which has the advantages of high-precision positioning, quick and reliable replacement, stepwise reuse of blades, and efficient use of resources, solving the problems of unstable machining quality caused by low positioning accuracy of the clamping structure, complicated and time-consuming blade replacement, and tool waste and high cost caused by the whole structure of the traditional hobbing cutter.

[0005] (II) Technical solution: In order to achieve the above-mentioned purposes of high-precision positioning, quick and reliable replacement, stepwise reuse of blades, and efficient use of resources, the present application provides the following technical solution: An easily replaceable high-usage indexable gear hobbing cutter, comprising: a tool body, the tool body is provided with blade grooves distributed in a circumferential array; a blade, the blade is an indexable blade, installed in the blade groove; a fastening mechanism, the fastening mechanism fixes the blade in the blade groove by the pressing force inclined to the radial direction component of the tool body.

[0006] Preferably, the inserts include long inserts and short inserts; the insert slots include long insert slots and short insert slots; the long inserts are arranged in the long insert slots, and the short inserts are arranged in the short insert slots; the long insert slots and the short insert slots are alternately arranged along the circumference of the cutter body.

[0007] Preferably, the fastening mechanism includes a screw, the axis of the screw forms an oblique angle with the radial direction of the cutter body, and the surface of the insert is provided with a mounting hole, through which the screw is used to fix the insert in the insert slot.

[0008] Preferably, the cutter body is provided with chip flutes, the chip flutes are arranged on the side of each insert slot, and the chips generated by the inserts are discharged into the chip flutes; the fastening mechanism includes a screw and a wedge, the wedge is arranged between the insert slot and the chip flute, the screw is arranged in the chip flute, the surface of the wedge close to the screw forms an angle with the surface of the wedge close to the insert, and the axis of the screw is parallel to the surface of the wedge close to the screw; when the screw is tightened in the chip flute, the wedge presses the insert, and the insert is fixed in the insert slot.

[0009] Preferably, the end of the wedge close to the outside of the insert slot is provided with a slope, and the slope guides the chips into the chip flute; the side of the chip flute close to the wedge is provided with a slope, and the slope guides the chips into the chip flute.

[0010] Preferably, a spring washer is arranged between the screw and the mounting surface of the chip flute.

[0011] Preferably, when the long inserts and the short inserts are arranged on the cutter body, the sizes of the long inserts and the short inserts are arranged in order from large to small, and the sizes of the long inserts and the short inserts are respectively the same as the sizes of the insert slots; when the inserts are arranged in the insert slots, the exposed thickness of the cutting surfaces of the inserts is unchanged.

[0012] Preferably, after the inserts are worn, the worn inserts can be removed from a current insert slot; and the removed inserts are arranged in another insert slot with a size matching that of the removed inserts.

[0013] Preferably, after the inserts are worn, the worn inserts are removed from the insert slots; the removed inserts are machined to change the sizes thereof, so as to obtain regenerated inserts; and the regenerated inserts are arranged in another insert slot with a size matching that of the regenerated inserts, or are arranged in the insert slots of other gear hobs.

[0014] (Three) beneficial effects: compared with the prior art, the present application provides an easy-to-replace high-usage indexable gear hobbing cutter, which has the following beneficial effects: 1, the easy-to-replace high-usage indexable gear hobbing cutter, by adopting the oblique fastening mechanism, the tightening direction of the screw and the radial direction of the cutter form an angle, compared with the traditional axial fastening mode, the contact area and the pressing force between the blade and the cutter groove are significantly increased, the rigidity and stability of the blade clamping are greatly improved, and the loosening or displacement of the blade under high-speed heavy cutting working condition is effectively avoided; At the same time, the structure adopts the design of long and short blade staggered cutting, the long blade is used as rough tooth to cut large excess, and the short blade is used as fine tooth to finish the tooth shape, realizing the integration of rough and fine machining, not only reasonably distributing the cutting load and reducing the machining vibration, but also greatly improving the cutting efficiency and machining surface quality; In addition, the oblique fastening design makes the depth and diameter of the threaded hole larger and deeper, improves the strength and durability of the threaded connection part, not only makes the blade replacement operation more simple and fast, reduces the downtime, but also effectively guarantees the production safety and machining efficiency.

[0015] 2, the easy-to-replace high-usage indexable gear hobbing cutter, by adopting the innovative locking structure of screw driving wedge, the tightening direction of the bolt is arranged along the diameter direction of the cutter holder, only need to tighten the screw in the normal way during assembly, the wedge inclined surface can automatically generate strong radial pressing force, the assembly process is simple and intuitive; It is especially convenient when disassembling and replacing the blade, because there is a certain angle between the wedge inclined surface and the screw axis, the screw does not need to be completely unscrewed, only need to withdraw one-half to two-thirds stroke, the wedge can fully retreat to release the pressing force of the blade, the blade can be easily taken out and replaced, greatly improving the maintenance efficiency. This design not only significantly improves the clamping rigidity and stability through the wedge inclined surface reinforcement principle, but also increases the effective contact area between the cutter head and the cutter holder, so that the pressing force distribution is more uniform and reliable. In addition, the structure provides more sufficient design space for the fastening threaded hole, which can configure larger diameter fastening thread and deeper threaded hole depth, significantly improving the strength and durability of the threaded connection part, making the overall structure more reliable and durable.

[0016] 3、The replaceable high-usage indexable gear hobbing cutter, through adopting the innovative structure of sequential design of cutter head size and gradientized cooperation of cutter holder installation slot, numbers the cutter heads in order from large to small (such as 1 / 2 / 3 / 4 / 5 / 6...), and sets the corresponding installation slots with gradually increasing size on the cutter holder, so as to realize the accurate matching of the cutter head and the cutter slot. In the use process, when the larger size cutter head (such as No. 1) is worn, it does not need to be discarded, but can be reduced in size to the next specification (such as No. 2) through secondary processing, and then installed in the corresponding installation slot of the cutter holder for continuous use, and the cycle is repeated until the minimum available specification. This step-by-step reuse method not only significantly prolongs the service life of the cutter head, greatly reduces the tool consumption cost, but also reduces material waste, and embodies the green manufacturing concept. At the same time, the structure design makes the cutter head replacement process simple and standardized, and the operator only needs to install according to the number to quickly complete the tool changing operation, effectively reduces the equipment downtime, improves the production efficiency, and provides a reliable tool management solution for large-scale continuous machining. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 It is a complete schematic diagram of the cutter body part of the application.

[0018] Figure 2 It is a left view schematic diagram of the cutter body of the application.

[0019] Figure 3 It is Figure 2 The first embodiment schematic diagram of P position.

[0020] Figure 4 It is Figure 2 The second embodiment schematic diagram of P position.

[0021] Figure 5 It is Figure 4 The A-A cross-sectional view schematic diagram.

[0022] Figure 6 It is a schematic diagram of the cutter slots of the third embodiment of the application.

[0023] In the figure: 1, cutter body; 11, cutter slot; 111, long cutter slot; 112, short cutter slot.

[0024] 2, insert; 21, long insert; 22, short insert; 23, installation hole; 24, regenerated insert.

[0025] 3, fastening mechanism; 31, screw; 32, wedge block; 321, inclined surface; 33, elastic pad.

[0026] 4, chip removal groove; 41, slope. DETAILED DESCRIPTION

[0027] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present application, but not all the embodiments of the present application. Based on the embodiments of the present application, all the other embodiments obtained by a person of ordinary skill in the art without creative work are within the protection scope of the present application.

[0028] Please refer to Figures 1-3 A replaceable high-usage indexable gear hobbing cutter comprises a cutter body 1, the cutter body 1 is provided with cutter grooves 11 distributed in an array along a circumference; a blade 2, the blade 2 is an indexable blade 2, and is installed in the cutter groove 11; and a fastening mechanism 3, the fastening mechanism 3 fastens and fixes the blade 2 in the cutter groove 11 through a pressing force inclined to a radial direction component of the cutter body 1. By adopting the obliquely arranged fastening mechanism 3, a stable included angle is formed between a tightening direction of a screw 31 and the radial direction of the cutter body 1. Compared with a traditional axial fastening mode, the structure significantly increases an effective contact area between the blade 2 and a bearing surface of the cutter groove 11 and a pressing force effect, greatly improves clamping rigidity and anti-vibration stability of the blade 2 under a high-speed heavy cutting condition, and completely avoids a micro-displacement or loosening phenomenon of the blade 2 caused by cutting force fluctuation in a machining process, thereby ensuring consistency and reliability of gear machining precision. The fastening mechanism 3 comprises the screw 31, an axis of the screw 31 forms an oblique included angle with the radial direction of the cutter body 1, the blade 2 is provided with a mounting hole 23 on a surface thereof, the screw 31 fastens the blade 2 in the cutter groove 11 through the mounting hole 23, the oblique fastening layout provides more sufficient design space for a threaded connection system, allows a larger nominal diameter fastening thread and a deeper thread hole depth to be adopted, and significantly enhances connection strength and anti-fatigue performance of the threaded pair. This design not only makes replacement operation of the blade 2 more convenient and fast, greatly shortens downtime, but also effectively improves equipment utilization and production safety, and provides reliable process guarantee for efficient and precise gear machining.

[0029] Please refer to Figures 4-5In the second embodiment, the tool body 1 comprises a chip flute 4 arranged on the side of each tool groove 11, and the chips generated by the insert 2 are discharged into the chip flute 4; the fastening mechanism 3 comprises a screw 31 and a wedge block 32, the tool groove 11 is separated from the chip flute 4 by the wedge block 32, the screw 31 is installed inside the chip flute 4, the side of the wedge block 32 close to the screw 31 and the side close to the insert 2 have an included angle, the axis of the screw 31 is parallel to the surface of the wedge block 32 on the side close to the screw 31, so when the screw 31 is tightened in the chip flute 4, the wedge block 32 is driven to move axially, and the axial force is converted into radial compression force by the inclined surface 321, so as to firmly fix the insert 2 in the tool groove 11; the wedge block 32 type locking mechanism is designed by mechanics optimization, which significantly increases the force bearing area of the insert 2, improves the clamping rigidity and stability, and effectively prevents the insert 2 from moving during machining. At the same time, the end of the wedge block 32 close to the outside of the tool groove 11 is provided with a chip guiding inclined surface 321, which forms a continuous and smooth chip discharge channel with the guide slope surface 41 on the side of the chip flute 4, and together guide the chips to smoothly enter the chip flute 4, avoiding the influence of chip accumulation on the machining quality. In addition, the elastic pad 33 arranged between the screw 31 and the mounting surface of the chip flute 4 effectively prevents the screw 31 from loosening under vibration conditions, ensuring the long-term stability of the clamping force. This integrated design of chip flow guiding, wedge block 32 force increasing and anti-loosening protection not only improves the reliability of the tool, but also greatly simplifies the insert 2 replacement process, significantly improves the maintenance efficiency; at the same time, the end of the wedge block 32 close to the outside of the tool groove 11 has an inclined surface 321, which guides the chips into the chip flute 4, and the side close to the wedge block 32 of the chip flute 4 is provided with a slope surface 41, which guides the chips into the chip flute 4, together guiding the chips to smoothly enter the chip flute 4, avoiding the influence of chip accumulation on the machining quality; the elastic pad 33 is arranged between the screw 31 and the mounting surface of the chip flute 4, which effectively prevents the screw 31 from loosening under vibration conditions, ensuring the long-term stability of the clamping force.

[0030] Please refer to Figure 6In the third embodiment, when the long blades 21 and the short blades 22 are arranged in an array on the cutter body 1, the sizes of the long blades 21 and the short blades 22 are arranged in order from large to small, and the sizes of the long blades 21 and the short blades 22 are the same as those of the respective blade grooves 11; when the blades 2 are installed inside the blade grooves 11, the exposed thickness of the cutting faces of the blades 2 remains unchanged, ensuring the stability and precision consistency of the cutting process; a method for repairing and reusing the blades of a gear hobbing cutter, after the blades 2 are worn, the blades 2 can be disassembled from a current blade groove 11; the disassembled blades 2 are installed into another blade groove 11 with a size matching that of the blades 2; or after the blades 2 are worn, the worn blades 2 are disassembled from the blade grooves 11; the disassembled blades 2 are subjected to cutting processing to change their sizes, obtaining regenerated blades 24; the regenerated blades 24 are installed into another blade groove 11 with a size matching that of the regenerated blades 24 on the cutter body 1, or into the blade grooves 11 of other gear hobbing cutters, the difference between the two methods is that the former cannot guarantee that all the blade grooves 11 can obtain matching blades 2, but reduces the processing steps, and the latter can save materials to the greatest extent, so that damaged tools only need to replace the largest size blades 2, realizes the step-by-step recycling of the blades 2, significantly prolongs the service life of the cutter, and greatly reduces the use cost of the cutter.

[0031] Please refer to Figures 1-3 The blades 2 include long blades 21 and short blades 22; the blade grooves 11 are divided into long blade grooves 111 and short blade grooves 112; the long blades 21 are arranged in the long blade grooves 111, and the short blades 22 are arranged in the short blade grooves 112; the long blade grooves 111 and the short blade grooves 112 are alternately distributed along the circumference of the cutter body 1; this alternating distribution design makes the long blades 21 serve as rough cutting teeth to undertake the main material removal task, and the short blades 22 serve as finishing cutting teeth to be responsible for the final tooth profile finishing, realizing the integration of rough and finish machining; the combination of long and short blades 22 can also prolong the overall service life of the cutter, and when one type of blade 2 is worn, only the blades 2 of this type need to be replaced, reducing the use cost.

[0032] In summary, the replaceable high-usage indexable gear hobbing cutter adopts a plurality of innovative structural designs. Firstly, the obliquely arranged fastening mechanism 3 makes the tightening direction of the screw 31 form an angle with the radial direction of the cutter body 1, significantly increasing the contact area and compression force between the insert 2 and the cutter groove 11, greatly improving the clamping rigidity and stability of the insert 2, and effectively avoiding the problem of insert 2 loosening or displacement under high-speed heavy cutting conditions. At the same time, the long and short inserts 22 are staggered in the cutting design, with the long insert 21 performing rough cutting teeth for large amount of cutting, and the short insert 22 as a finishing tooth to complete the tooth shape finishing, realizing rough and finishing machining integration, reasonably distributing cutting load, reducing machining vibration, and improving machining efficiency and surface quality. Secondly, in the second embodiment, the innovative locking structure of the screw 31 driving the wedge block 32 is adopted, which significantly improves the clamping rigidity through the wedge block 32 inclined surface 321 force amplification principle. During assembly, only the conventional tightening of the screw 31 can generate strong radial compression force, and during disassembly, the screw 31 only needs to be withdrawn by one-half to two-thirds of the stroke to release the compression of the insert 2, greatly improving the maintenance efficiency. At the same time, this structure provides more adequate design space for the fastening thread hole, which can be configured with larger diameter and deeper thread, enhancing the connection strength and durability. In addition, in the third embodiment, through the innovative scheme of matching the size serialization of the cutter head with the gradient of the cutter holder mounting slot, the cutter head is numbered from large to small according to size and matched with the corresponding mounting slot, the worn cutter head can be reduced in size to the next specification through secondary processing for continued recycling, significantly extending the tool life, reducing consumption cost, and reducing material waste. At the same time, the standardized replacement process enables the operator to quickly complete the tool replacement operation according to the number, effectively reducing downtime, improving production efficiency, providing a reliable tool management solution for large-scale continuous machining, and fully embodying the modern manufacturing concept of high efficiency, precision and green.

[0033] It should be noted that, in the present document, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by "comprises... a" does not, without more constraints, exclude the presence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0034] While embodiments of the application have been shown and described, it is to be understood that the embodiments described are merely exemplary of the principles and application of the present application. Numerous modifications and adaptions can be effected without departing from the spirit and scope of the present application, which is not limited to the exact construction and arrangement described. It is intended, therefore, to cover all modifications and adaptions that fall within the scope of the claims and their equivalents.

Claims

1. A high-usage indexable gear hob with easy replacement, comprising: The tool body (1) is provided with tool grooves (11) arranged in a circumferential array; the tool blade (2) is a indexable tool blade (2) installed in the tool groove (11); characterized in that further comprising: a fastening mechanism (3) which fastens the tool blade (2) in the tool groove (11) by a pressing force inclined to the radial direction component of the tool body (1); the tool body (1) comprises a chip flute (4) arranged on the side of each tool groove (11), and the chips generated by the tool blade (2) are discharged into the chip flute (4); the fastening mechanism (3) comprises a screw (31) and a wedge block (32), the tool groove (11) and the chip flute (4) are separated by the wedge block (32), the screw (31) is installed inside the chip flute (4), and the side of the wedge block (32) close to the screw (31) and the side close to the tool blade (2) have an included angle, the axis of the screw (31) is parallel to the surface of the wedge block (32) towards the screw (31) side; when the screw (31) is tightened inside the chip flute (4), the wedge block (32) presses the tool blade (2), and the tool blade (2) is fixed in the tool groove (11).

2. The high-usage indexable gear hob as set forth in claim 1, wherein: The wedge block (32) has a bevel (321) at the end towards the outside of the tool groove (11), which guides the chips into the chip flute (4); the chip flute (4) is provided with a slope (41) on the side close to the wedge block (32), which guides the chips into the chip flute (4).

3. The high-usage indexable gear hob as set forth in claim 1, wherein: A spring washer (33) is arranged between the screw (31) and the mounting surface of the chip flute (4).

4. The easily replaceable high usage indexable gear hob according to claim 1, wherein: The tool body (1) is arranged with long tool blades (21) and short tool blades (22) in an array, the sizes of the long tool blades (21) and the short tool blades (22) are arranged in order from large to small, and the sizes of the long tool blades (21) and the short tool blades (22) are respectively the same as those of each tool groove (11); when the tool blade (2) is installed in the tool groove (11), the exposed thickness of the cutting surface of the tool blade (2) remains unchanged.

5. A high-usage indexable gear hob as defined in claim 4, wherein: After the tool blade (2) is worn, the tool blade (2) can be disassembled from a current tool groove (11); the disassembled tool blade (2) is installed in another tool groove (11) with a size matching that of the tool blade (2).

6. A high-usage indexable gear hob as defined in claim 4, wherein: After the tool blade (2) is worn, the worn tool blade (2) is disassembled from the tool groove (11); the disassembled tool blade (2) is subjected to cutting processing to change its size, obtaining a regenerated tool blade (24); the regenerated tool blade (24) is installed in another tool groove (11) with a size matching that of the regenerated tool blade (24) on the tool body (1), or in the tool groove (11) of other gear hobs.

7. The indexable high usage indexable gear hob according to claim 4, wherein: The blade (2) comprises a long blade (21) and a short blade (22); the blade groove (11) is divided into a long blade groove (111) and a short blade groove (112); the long blade (21) is arranged in the long blade groove (111), and the short blade (22) is arranged in the short blade groove (112); the long blade groove (111) and the short blade groove (112) are alternately distributed along the circumference of the cutter body (1).

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