Method for machining face gear through vertical gear shaping machine
By installing a bevel gear pair device and a conventional gear shaper on a vertical gear shaper, efficient machining of face gears is achieved, solving the problems of high cost and equipment compatibility of gear hobbing machines, and improving the machining accuracy and transmission efficiency of face gears.
Patent Information
- Application Number
- CN202511609215.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-05
- Publication Date
- 2026-01-06
AI Technical Summary
Existing gear hobbing machines are difficult to process face gears efficiently, and there are problems such as high cost, high precision requirements, thermal deformation and tool wear. In addition, the equipment compatibility of small and medium-sized enterprises is insufficient.
A pair of bevel gears with a 90° shaft angle and the same number of teeth is used to convert the vertical rotation of the workpiece shaft of the vertical gear shaper into a horizontal rotation. The reciprocating, circumferential, indexing, and radial feed movements of the gear shaper are combined with conventional gear shaper cutters to achieve the machining of face gears.
It reduces processing costs, improves the surface quality and dimensional stability of face gears, enhances the versatility of machine tools, reduces thermal deformation and tool wear, and ensures accurate tooth profile generation and transmission efficiency.
Smart Images
Figure CN121267264A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of gear processing technology, and specifically to a method for processing face gears using a vertical gear shaper. Background Technology
[0002] Face gears are a special type of gear whose tooth surfaces are located on the end face of the gear. They typically mesh with involute cylindrical gears to achieve transmission with a shaft angle of 90°. Face gears have wide applications in aerospace, automotive, marine, and precision machinery fields, such as for power distribution in helicopter transmission systems or torque distribution in automotive differentials. Due to the complex tooth profile of face gears, their machining accuracy directly affects transmission efficiency, noise level, and service life. Therefore, face gear machining methods have always been a key research focus in the gear manufacturing field.
[0003] In existing technologies, the machining of face gears mainly relies on gear hobbing machines. The basic principle of this method is to generate the tooth profile through the rotation of the hob and the rotation of the workpiece. Specifically, when machining face gears, the hob needs to be designed to mimic the involute cylindrical gear that meshes with the face gear; that is, the tooth profile of the hob must correspond to the involute curve of the meshing gear. However, this machining method has significant limitations. First, conventional gear hobbing machines are mainly used for machining involute cylindrical gears. When applied to face gears, the hob must be specially modified, including adjusting the helix angle, module, and number of teeth to adapt to the end face tooth profile of the face gear. This modification not only increases the manufacturing difficulty of the hob but also significantly increases the economic cost. Because hobs are precision tools, their materials are usually high-speed steel or cemented carbide, and any customized design requires additional machining steps, such as precision grinding and heat treatment, which can lead to a 20%-50% increase in cost. Second, existing gear hobbing methods have high requirements for machine tools, requiring that the angle between the hob axis and the workpiece axis be precisely 90°; otherwise, the accuracy of the tooth profile will be affected. In addition, the continuous cutting of the hob during gear hobbing generates a large amount of heat, which can cause workpiece deformation or accelerated tool wear, thereby affecting the surface roughness and meshing performance of the gear.
[0004] Furthermore, existing gear hobbing machines face compatibility issues. Many small and medium-sized enterprises own gear hobbing machines with standard configurations that cannot be directly adapted to face gear machining, limiting the application of face gears in small-scale production. In contrast, vertical gear shapers, as a common gear machining tool, are characterized by their simple structure and flexible operation, and are mainly used for machining internal gears, external gears, and splines, but have not traditionally been used for face gear machining. This is because the workpiece shaft of a vertical gear shaper is usually arranged vertically, while face gear machining requires horizontal rotational motion to achieve end face cutting. If a vertical gear shaper is used directly, it will result in a mismatch in motion directions, making it impossible to form the correct tooth profile. Summary of the Invention
[0005] In view of this, the purpose of this invention is to solve the machining problem of face gears and to provide a method for machining face gears using a vertical gear shaper. This method uses a pair of bevel gears with a 90° shaft angle and the same number of teeth to convert the vertical rotational motion of the workpiece shaft of the vertical gear shaper into a horizontal rotational motion, without changing the machine tool transmission ratio. Under the condition that the number of teeth on the shaper cutter is 1 to 3 more than the meshing involute cylindrical gear, the face gear is machined using the machine tool's reciprocating motion, circumferential feed, tooth splitting, radial feed, and tool deflection movements.
[0006] To achieve the above objectives, the present invention provides the following technical solution: A method for machining face gears using a vertical gear shaper includes the following steps: S1. A pair of bevel gears with a 90° shaft intersection angle and the same number of teeth are used. The bevel gear pair is installed on the bed of a vertical gear shaper, so that the center line of the vertical gear shaper cutter shaft, the center line of the first bevel gear shaft of the bevel gear pair, the center line of the second bevel gear shaft, and the center line of the machine tool rotary table are all in the same plane; the machine tool rotary table drives the first bevel gear shaft to rotate through the second bevel gear shaft. S2. Mount the face gear to be processed onto the first bevel gear shaft; S3. Select a gear shaper cutter. The number of teeth on the gear shaper cutter is 1 to 3 more than the number of teeth on the involute cylindrical gear that meshes with the face gear. S4. The face gear is machined by using the reciprocating motion of the cutter shaft, the circumferential feed motion, the tooth splitting motion, the radial feed motion, and the tool deflection motion of the vertical gear shaper.
[0007] Furthermore, the bevel gear pair device includes an upper housing, a lower housing, a first bevel gear shaft, and a second bevel gear shaft; the first bevel gear shaft and the second bevel gear shaft are mounted in the upper housing and the lower housing through bearings, with an angle of 90° between the shafts; the second bevel gear shaft meshes with the first bevel gear shaft; the second bevel gear shaft is connected to the machine tool rotary table to realize the motion conversion from the vertical direction to the horizontal direction.
[0008] Furthermore, the second bevel gear shaft has the same number of teeth as the first bevel gear shaft, so the machine tool transmission ratio is not changed.
[0009] Furthermore, the gear shaper is a conventional gear shaper used for machining involute cylindrical gears, and is directly used for face gear machining.
[0010] Furthermore, the lower housing is fixedly mounted on the bed of the vertical gear shaper and is connected by bolts, with the second bevel gear shaft housed therein.
[0011] Furthermore, it includes a connecting plate, one end of which is connected to the machine tool rotary table via a T-screw, and the other end is connected to the second bevel gear shaft, so as to directly transmit the rotational motion of the rotary table to the second bevel gear shaft.
[0012] The beneficial effects of this invention are as follows: First, the method in this invention utilizes the intermittent cutting principle of a gear shaper, i.e., the reciprocating motion of the cutter shaft for cutting, which differs from the continuous cutting of a gear hobbing machine. Intermittent cutting allows for heat dissipation during non-cutting phases, thereby reducing heat accumulation, lowering the risk of workpiece thermal deformation and tool thermal wear, and improving the surface quality and dimensional stability of the face gear. Simultaneously, the combination of circumferential feed motion and indexing motion ensures accurate tooth profile generation and uniform tooth spacing, avoiding vibration accumulation that may occur in continuous cutting. Radial feed motion allows for gradual adjustment of the depth of cut, achieving progressive machining, further controlling stress concentration, and improving tooth root strength. The tool-receiving motion effectively avoids interference between the tool and the workpiece, ensuring the safety and continuity of the machining process. In particular, the design of the gear shaper cutter having 1-3 more teeth than the meshing involute cylindrical gear optimizes tooth profile matching from a meshing principle perspective, reduces meshing clearance, improves transmission efficiency, and reduces noise.
[0013] Secondly, this method requires no modification to conventional gear shapers and can be directly used for face gear machining. This lowers the tool preparation threshold, as standard gear shapers are widely available, eliminating the need for custom-made tools. Furthermore, by introducing a pair of bevel gears with a 90° shaft angle and the same number of teeth, this reusable machine tool accessory requires only one-time assembly and installation. The core of this device is the conversion of vertical rotation to horizontal rotation while maintaining a constant transmission ratio, ensuring motion accuracy and avoiding the introduction of transmission errors. This simplifies operation and expands the machining range of ordinary vertical gear shapers from traditional cylindrical gear machining to face gear machining, enhancing the machine tool's versatility.
[0014] Furthermore, the device features a compact structure, comprising an upper housing, a lower housing, a first bevel gear shaft, and a second bevel gear shaft. These components are mounted using bearings, ensuring stable positioning, reliable connection, and a clear operational relationship: the machine tool's rotary table drives the first bevel gear shaft via a connecting plate and the second bevel gear shaft, achieving horizontal rotation of the workpiece. This transmission conversion is based on the orthogonal meshing principle of bevel gears, guaranteeing smooth motion and consistent precision. Compared to the complex tool adaptations of gear hobbing machines, this method utilizes the machine tool's existing motion trajectory, making it more versatile in principle and applicable to various gear specifications.
[0015] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description
[0016] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the bevel gear pair device used in the method of this invention.
[0017] Reference numerals in the attached drawings: 1-First bevel gear shaft; 2-Second bevel gear shaft; 3-Face gear; 4-Upper housing; 5-Connecting disc; 6-Lower housing; 7-Machine tool rotary table; 8-Vertical gear shaper machine bed; 9-Gear shaper cutter. Detailed Implementation
[0018] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.
[0019] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.
[0020] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.
[0021] Example 1 like Figure 1 The image shows a method for machining face gears using a vertical gear shaper, comprising the following steps: S1. A pair of bevel gears with a 90° shaft angle and the same number of teeth is used. The bevel gear pair is mounted on the vertical gear shaper machine bed 8, so that the centerline of the vertical gear shaper cutter shaft, the centerline of the first bevel gear shaft 1 and the second bevel gear shaft 2 of the bevel gear pair, and the centerline of the machine tool rotary table 7 are all in the same plane. The machine tool rotary table 7 drives the first bevel gear shaft 1 to rotate through the second bevel gear shaft 2. Specifically, the bevel gear pair includes an upper housing 4, a lower housing 6, a first bevel gear shaft 1, and a second bevel gear shaft 2. The first bevel gear shaft 1 and the second bevel gear shaft 2 are mounted in the upper housing 4 and the lower housing 6 through bearings, with a 90° shaft angle. The second bevel gear shaft 2 meshes with the first bevel gear shaft 1 and is connected to the machine tool rotary table 7 to realize the conversion of vertical to horizontal motion. The bearing is located at the shaft end, providing rotational support and friction reduction; the skeleton oil seal and O-ring are located at the housing interface to prevent lubricating oil leakage; the round nut is located at the shaft end to fix the shaft position; the cover plate is located on the side of the upper housing 4 to provide a sealing function. The second bevel gear shaft 2 has the same number of teeth as the first bevel gear shaft 1, without changing the machine tool transmission ratio. The lower housing 6 is fixedly installed on the vertical gear hobbing machine bed 8 and is connected by bolts, enclosing the second bevel gear shaft 2 within it. One end of the connecting plate 5 is connected to the machine tool rotary table 7 by a T-screw, and the other end is connected to the second bevel gear shaft 2, directly transmitting the rotational motion of the rotary table to the second bevel gear shaft 2.
[0022] S2. Mount the face gear 3 to be processed onto the first bevel gear shaft 1.
[0023] S3. Select the gear shaper 9. The number of teeth on the gear shaper 9 is 1 to 3 more than the number of teeth on the involute cylindrical gear that meshes with the face gear 3. The gear shaper 9 is a conventional gear shaper for machining involute cylindrical gears and does not require parameter modification; it can be directly used for machining the face gear 3.
[0024] S4. The face gear 3 is machined by using the reciprocating motion of the cutter shaft, the circumferential feed motion, the tooth splitting motion, the radial feed motion, and the tool deflection motion of the vertical gear shaper.
[0025] During the machining process, the rotary table 7 of the vertical gear shaper rotates, driving the connecting plate 5 to rotate synchronously via T-screws. The rotation of the connecting plate 5, in turn, drives the second bevel gear shaft 2 to rotate via a flat key. The rotation of the second bevel gear shaft 2, in turn, drives the first bevel gear shaft 1, which meshes with it, to rotate. The rotation of the first bevel gear shaft 1, in turn, drives the gear 3 to be machined, mounted on the first bevel gear shaft 1, to rotate, thus maintaining a 1:1 transmission ratio without changing the original transmission ratio of the machine tool and avoiding the introduction of transmission errors. The vertical gear shaper utilizes the reciprocating motion of the cutter shaft for cutting, the circumferential feed motion to generate the tooth profile, the tooth spacing motion to control the tooth pitch, the radial feed motion to adjust the depth of cut, and the tool deflection motion to avoid interference, thereby machining the gear 3.
[0026] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.
Claims
1. A method of machining a face gear with a vertical gear shaper, characterized in that, It comprises the following steps: S1, using a pair of shaft angle of 90° and the same number of bevel gear pair device, the bevel gear pair device is installed on the bed of vertical gear shaping machine, so that the vertical gear shaping machine cutter shaft axis, the first bevel gear shaft axis of the bevel gear pair device, the second bevel gear shaft axis and the machine tool rotary table axis are in the same plane; the machine tool rotary table drives the first bevel gear shaft to rotate through the second bevel gear shaft; S2, the face gear to be processed is installed on the first bevel gear shaft; S3, select the gear shaping cutter, the tooth number ratio of the gear shaping cutter is 1-3 more than that of the involute cylindrical gear engaged with the face gear; S4, using the up and down reciprocating motion, circular feed motion, tooth division motion, radial feed motion and tool relief motion of the cutter shaft of the vertical gear shaping machine, the face gear is processed.
2. The method of claim 1, wherein, The bevel gear pair device comprises an upper box body, a lower box body, a first bevel gear shaft and a second bevel gear shaft; the first bevel gear shaft and the second bevel gear shaft are installed in the upper box body and the lower box body through bearings, and the shaft angle is 90°; the second bevel gear shaft is engaged with the first bevel gear shaft, and the second bevel gear shaft is connected with the machine tool rotary table to realize the motion conversion from the vertical direction to the horizontal direction.
3. The method of claim 1, wherein, The second bevel gear shaft and the first bevel gear shaft have the same number of teeth, without changing the transmission ratio of the machine tool.
4. The method of claim 1, wherein, The gear shaping cutter is a conventional gear shaping cutter for processing involute cylindrical gears, which is directly used for face gear processing.
5. The method of claim 2, wherein, The lower box body is fixedly installed on the bed of the vertical gear shaping machine and is fixedly connected through bolts, and the second bevel gear shaft is covered in the lower box body.
6. The method of claim 5, wherein, The connecting disc is connected with the second bevel gear shaft at one end and with the machine tool rotary table at the other end through T-shaped screws, so that the rotary motion of the rotary table is directly transmitted to the second bevel gear shaft.