Compound gear slotting roller machine tool and rough and finish machining device and method thereof

Abstract

The invention discloses a compound gear slotting and rolling machine tool and a rough and finish machining device and method thereof. The rough and finish machining device comprises a series connection main shaft connected to the machine tool through a rotary table, a first cutter arranged at one end of the series connection main shaft, a second cutter arranged at the other end of the series connection main shaft and a positioning measuring head arranged between the first cutter and the second cutter and connected to the series connection main shaft. The rough machining tool and the finish machining tool are arranged to cooperate with each other, the rough machining tool bears most cutting output, the situation that the finish machining tool bears too large cutting stress is avoided, meanwhile, the rough machining tool is of an indexable insert blade type structure, the finish machining tool is of an integrated structure, and the rough machining tool and the finish machining tool meet different machining requirements; the overall abrasion speed of the tool is obviously reduced, the service life is prolonged, the tool changing frequency and the inventory cost are reduced, and good practicability is achieved.

Description

Technical Field

[0001] This invention belongs to the technical field of gear rolling machine tools, and particularly relates to a composite gear rolling machine tool and its roughing and finishing apparatus and method. Background Technology

[0002] Gear rolling machines are a new type of gear processing equipment that has developed rapidly in the last decade or so. With their core advantages of high efficiency and high precision, they have been gradually applied to various industries and enterprises with batch gear processing needs, becoming an important technical equipment in the gear manufacturing field. Gear rolling, also known as gear turning, gear scraping, or gear cutting, is characterized by the tool axis and workpiece axis rotating synchronously at high speed during processing, achieving cutting through the meshing motion of the tool and workpiece. While this process can significantly improve processing efficiency, the concentrated meshing cutting load leads to relatively faster tool wear. Currently, the mainstream rolling strategy in the industry (as shown in Figure 1) uses a single tool throughout the entire process, requiring all steps from the first cut to the final finishing of the left and right tooth surfaces to be completed in one go. In this processing mode, the cutting edge must cut off most of the chips before reaching the target tooth depth, resulting in the cutting edge bearing significant cutting stress for a long time, further aggravating tool wear. This affects processing stability and also poses a hidden danger to subsequent production efficiency and cost control. In actual mass production, due to differences in workpiece materials, modules, and cutting process parameters, the commonly used S390 powder metallurgy high-speed steel conical cutting tools have a short lifespan. Typically, after machining 30-50 workpieces, they need to be returned to the factory for re-grinding and recoating. This situation leads to a series of problems: First, multiple machine stops are required daily for tool replacement, and a large number of spare tools need to be stockpiled to compensate for the re-grinding intervals, significantly increasing inventory costs. Second, equipment parameters need to be readjusted after each tool change, which not only prolongs production support time but also easily affects machining accuracy due to parameter deviations. The aforementioned problems of "frequent tool changes - high inventory - time-consuming parameter adjustments" caused by the single-tool machining strategy severely restrict the improvement of production efficiency and tool cost control. Therefore, there is an urgent need for a composite gear rolling machine and its roughing and finishing device and method. Summary of the Invention

[0003] To address some or all of the technical problems existing in the prior art, the present invention provides a composite gear rolling machine and its roughing and finishing apparatus and method.

[0004] In one aspect of the present invention, a roughing and finishing apparatus for a compound gear rolling machine is provided. The roughing and finishing apparatus is disposed on one side of the machine tool and includes a series spindle connected to the machine tool via a rotary table, a first cutting tool disposed at one end of the series spindle, a second cutting tool disposed at the other end of the series spindle, and a positioning probe disposed between the first cutting tool and the second cutting tool and connected to the series spindle, wherein: The serial spindle includes a housing, a first rotating shaft and a second rotating shaft disposed within the housing and connected to each other, and a sensor disposed between the first rotating shaft and the second rotating shaft. A drive unit is connected to the outer periphery of the first rotating shaft. A first clamp is disposed at one end of the first rotating shaft, and a transition bearing is disposed between the other end and the housing. The first clamp is connected to the first cutting tool through a first tool bar. A second clamp is disposed at one end of the second rotating shaft, and the second clamp is connected to the second cutting tool through a second tool bar. A first bearing assembly is disposed between the first rotating shaft and the housing, and a second bearing assembly is disposed between the second rotating shaft and the housing. A cable arrangement compartment is disposed on the top of the housing.

[0005] Furthermore, in the aforementioned composite gear rolling machine and its roughing and finishing apparatus, the first shaft and the second shaft are connected by a spline.

[0006] Furthermore, in the aforementioned composite gear rolling machine and its roughing and finishing apparatus, the cable arrangement compartment is equipped with a power cable interface, a motor temperature sensing wire interface, a bearing temperature sensor cable interface, an encoder cable interface, an air seal pipeline interface, and a water cooling pipeline interface.

[0007] Furthermore, in the above-mentioned composite gear rolling machine and its roughing and finishing device, the first clamp end face is provided with a first groove, the first tool bar is clamped in the first groove, the second clamp end face is provided with a second groove, and the second tool bar is clamped in the second groove.

[0008] Furthermore, in the above-mentioned composite gear rolling machine and its roughing and finishing apparatus, the first cutting tool is a finishing tool, and the finishing tool is an integral cutting tool.

[0009] Furthermore, in the above-mentioned composite gear rolling machine and its roughing and finishing device, the second tool is a roughing tool, and the roughing tool is an indexable insert type tool.

[0010] Furthermore, in the aforementioned composite gear rolling machine and its roughing and finishing apparatus, the sensor is an angle encoder.

[0011] Furthermore, in the aforementioned composite gear rolling machine and its roughing and finishing apparatus, the drive unit is a direct-drive motor.

[0012] The composite gear rolling machine and its roughing and finishing methods provided by this invention include: Step 1: Place the workpiece to be processed under the roughing and finishing device on one side of the machine tool; Step 2: Rotate the turntable so that the second tool is above the workpiece, start the drive unit, and perform the first machining on the workpiece to machine the basic tooth groove. The first machining will remove 80% to 90% of the total cutting amount of the workpiece. Step 3: Rotate the turntable so that the first tool is above the workpiece, start the drive unit, and perform a second machining on the workpiece. The first tool will machine a complete tooth groove based on the basic tooth groove. The second machining will remove the remaining 10% to 20% of the cutting amount of the entire workpiece.

[0013] In another aspect of the invention, a composite gear rolling machine tool is also provided, the composite gear rolling machine tool including the above-described roughing and finishing apparatus.

[0014] The composite gear rolling machine and its roughing and finishing apparatus and method of the present invention have the following advantages and positive effects: (1) By setting up roughing tools and finishing tools to cooperate, the roughing tools bear most of the cutting amount, avoiding the finishing tools from bearing excessive cutting stress. At the same time, the roughing tools adopt an indexable insert structure, while the finishing tools adopt an integral structure. The two are adapted to different processing needs, which significantly reduces the overall wear rate of the tools, extends the service life, and reduces the tool replacement frequency and inventory costs. The roughing tools only need to be replaced with inserts, without the need for overall replacement, which reduces the number of tool replacements. At the same time, due to the extended tool service life, the number of spare tools required is reduced, which significantly reduces inventory costs. (2) The present invention realizes the rapid switching of positioning probe, roughing tool and finishing tool by setting a turntable, without moving the workpiece or machine tool body. At the same time, the slot connection structure of the tool holder and the clamp facilitates the quick disassembly and assembly of the tool, reduces the time for tool changing and parameter adjustment, improves production efficiency and ensures machining accuracy. A high-precision angle encoder is used to detect the angle position of the rotating shaft in real time to ensure that the tool rotates synchronously. The integral structure of the finishing tool further improves the machining accuracy of the tooth surface and effectively avoids the influence of parameter adjustment deviation on machining accuracy. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for further understanding of the embodiments of the present invention and constitute a part of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 It is a single-spindle gear rolling machine tool in the existing technology; Figure 2This is a schematic diagram of the first processing state of the roughing and finishing device of the composite gear rolling machine of the present invention; Figure 3 This is a schematic diagram of the second processing state of the roughing and finishing device of the composite gear rolling machine tool of the present invention; Figure 4 This is a schematic diagram of the positioning structure of the roughing and finishing device of the composite gear rolling machine tool of the present invention; Figure 5 This is a schematic diagram of the structure of the roughing and finishing device of the composite gear rolling machine tool of the present invention, with the main spindle connected in series.

[0016] Explanation of reference numerals in the attached figures: 1. First cutting tool; 11. First tool holder; 12. First rotating shaft; 13. First clamp; 14. First bearing assembly; 2. Second cutting tool; 21. Second tool holder; 22. Second rotating shaft; 23. Second clamp; 24. Second bearing assembly; 3. Serial spindle; 31. Housing; 32. Transition bearing; 4. Positioning probe; 5. Turntable; 6. Drive unit; 7. Cable tray; 8. Sensor; 100. Workpiece; 200. Machine tool. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0018] This invention provides a composite gear rolling machine and its roughing and finishing apparatus and method, such as... Figures 1 to 5 As shown, the roughing and finishing device of the compound gear rolling machine is located on one side of the machine tool 200. The roughing and finishing device includes a series spindle 3 connected to the machine tool 200 via a rotary table 5, a first tool 1 located at one end of the series spindle 3, a second tool 2 located at the other end of the series spindle 3, and a positioning probe 4 located between the first tool 1 and the second tool 2 and connected to the series spindle 3. Wherein: The serial spindle 3 includes a housing 31, a first rotating shaft 12 and a second rotating shaft 22 disposed within the housing 31 and connected to each other, and a sensor 8 disposed between the first rotating shaft 12 and the second rotating shaft 22. A drive unit 6 is connected to the outer periphery of the first rotating shaft 12. The drive unit 6 provides power for the rotation of the first rotating shaft 12, ensuring that the first rotating shaft 12 can achieve high-speed and precise speed adjustment according to processing requirements. A first clamp 13 is provided at one end of the first rotating shaft 12, and a transition bearing 32 is provided between the other end and the housing 31. The transition bearing 32 can reduce the friction between the first rotating shaft 12 and the housing 31 during rotation, ensuring the stability and smoothness of the rotation of the first rotating shaft 12, and at the same time, it plays an axial positioning role for the first rotating shaft 12. The first clamp 13... The first tool holder 11 is connected to the first tool 1. The second rotating shaft 22 is provided with a second clamp 23 at one end. The second clamp 23 is connected to the second tool 2 via the second tool holder 21. A first bearing assembly 14 is provided between the first rotating shaft 12 and the housing 31. A second bearing assembly 24 is provided between the second rotating shaft 22 and the housing 31. The first bearing assembly 14 and the second bearing assembly 24 provide radial support and positioning for the first rotating shaft 12 and the second rotating shaft 22, respectively, further improving the coaxiality and stability of the rotating shaft and avoiding the impact of the rotating shaft shaking on the machining accuracy. A cable arrangement compartment 7 is provided on the top of the housing 31. The cable arrangement compartment 7 is used to integrate various pipelines required by the device, avoiding interference problems caused by messy pipeline distribution, and facilitating later maintenance and repair.

[0019] In one specific embodiment, in the roughing and finishing apparatus of the composite gear rolling machine of the present invention, the first rotating shaft 12 and the second rotating shaft 22 are connected by a spline. More specifically, the first rotating shaft 12 and the second rotating shaft 22 are connected by a small-backlash spline. The spline connection structure can ensure the synchronous rotation between the first rotating shaft 12 and the second rotating shaft 22, and at the same time realize reliable torque transmission, avoid relative slippage between the two during transmission, ensure the synchronous accuracy of tool rotation, and thus improve the machining quality.

[0020] In one specific embodiment, the roughing and finishing apparatus of the composite gear rolling machine of the present invention includes a power cable interface, a motor temperature sensing wire interface, a bearing temperature sensor cable interface, an encoder cable interface, an air seal pipe interface, and a water cooling pipe interface within the cable arrangement compartment 7. The power cable interface is used to connect the power cables required by the drive unit 6 and other electrical components. The motor temperature sensing wire interface is used to connect the temperature sensing wire for detecting the temperature of the drive unit 6, enabling real-time monitoring of the operating temperature of the drive unit 6 and preventing equipment damage due to excessive temperature. The bearing temperature sensor cable interface is used to connect the temperature sensors for detecting the first bearing group 14, the second bearing group 24, and the transition bearing 32, allowing real-time monitoring of the bearing's operating status and timely detection of abnormal wear or overheating problems. The encoder cable interface is used to connect the cable of the sensor 8, ensuring stable transmission of the sensor's data. The air seal pipe interface is used to connect to the air seal pipe, preventing chips and dust generated during processing from entering the housing 31 through gas sealing, protecting components such as the shaft and bearings. The water cooling pipe interface is used to connect to the water cooling pipe, providing cooling for the drive unit 6, bearings, and other heat-generating components, maintaining the operating temperature of the components within a reasonable range, and extending their service life.

[0021] In one specific embodiment, in the roughing and finishing apparatus of the composite gear rolling machine of the present invention, the end face of the first clamp 13 is provided with a first groove, and the first tool bar 11 is clamped in the first groove. The end face of the second clamp 23 is provided with a second groove, and the second tool bar 21 is clamped in the second groove. The groove structure can accurately position the tool bar, ensure the coaxiality between the tool bar and the clamp, and facilitate the quick disassembly and assembly of the tool bar, reduce the auxiliary time when changing tools, and improve the work efficiency.

[0022] As a specific embodiment, in the roughing and finishing device of the composite gear rolling machine of the present invention, the first tool 1 is a finishing tool, and the finishing tool is an integral tool. With this configuration, the integral structure can ensure the overall rigidity and accuracy of the tool, avoid the accuracy deviation caused by the splicing of tool components, and is suitable for the final finishing of the gear tooth surface, ensuring that the tooth profile accuracy and surface roughness of the gear after processing meet the usage requirements.

[0023] As a specific embodiment, in the roughing and finishing device of the composite gear rolling machine of the present invention, the second tool 2 is a roughing tool, which is an indexable insert tool. With this configuration, when the insert wears out, only the insert needs to be replaced to continue using the tool, without having to replace the entire tool, which significantly reduces the tool usage cost. At the same time, the indexable design facilitates quick insert replacement, further shortening the tool change time and adapting to the needs of mass production.

[0024] As a specific implementation, in the roughing and finishing apparatus of the composite gear rolling machine of the present invention, the sensor 8 is a high-precision angle encoder, which can detect the angular position information of the first rotating shaft 12 and the second rotating shaft 22 in real time, and transmit the detection data to the machine tool 200 control system. The control system adjusts the operating state of the drive unit 6 according to the data to ensure that the tool axis and the workpiece axis rotate synchronously, thereby ensuring the meshing accuracy between the tool and the workpiece 100 and improving the machining quality.

[0025] As a specific implementation, in the roughing and finishing device of the composite gear rolling machine tool of the present invention, the drive unit 6 is a direct drive motor, which can directly drive the first rotating shaft 12 to rotate without the need for an intermediate transmission mechanism, thereby reducing energy loss and error in the transmission process. It has the advantages of fast response speed, high transmission accuracy and stable operation, and can meet the high requirements of gear rolling machining for tool speed and accuracy.

[0026] The roughing and finishing method of the composite gear rolling machine of the present invention is implemented using the above-mentioned roughing and finishing apparatus, and specifically includes the following steps: Step 1: Place the workpiece 100 to be processed under the roughing and finishing device on one side of the machine tool 200; Step 2: After positioning the workpiece 100, rotate the turntable 5 so that the second tool 2 is above the workpiece 100. Start the drive unit 6 to drive the first rotating shaft 12 and the second rotating shaft 22 to rotate synchronously, thereby driving the second tool 2 to rotate. The second tool 2 and the workpiece 100 maintain synchronous meshing motion and perform the first machining on the workpiece 100 to machine the basic tooth groove. The first machining will remove 80% to 90% of the overall cutting amount of the workpiece 100. The first machining is roughing. Through roughing, most of the excess material is removed, reducing the cutting load of the subsequent finishing tool and avoiding accelerated wear of the finishing tool due to excessive cutting stress. Step 3: After rough machining, continue to rotate the turntable 5 so that the first tool 1 is above the workpiece 100. Start the drive unit 6 to drive the first tool 1 to rotate and perform a second machining on the workpiece 100. The first tool 1 will machine a complete tooth groove based on the basic tooth groove. The second machining will remove the remaining 10% to 20% of the cutting amount of the workpiece 100. The second machining is the finishing machining. The shape, size and surface quality of the tooth groove are precisely adjusted through finishing machining to finally produce a complete tooth groove that meets the requirements, ensuring that the machining accuracy and surface quality of the gear meet the usage requirements. For workpiece 100 that requires secondary finishing after rough machining and surface hardening heat treatment, as well as workpieces that require further processing after machining and inspection, the positioning probe 4 can detect the orientation of the machined tooth grooves, enabling the first tool 1 to automatically perform tool setting. More specifically, rotating the turntable 5 drives the serial spindle 3 and the positioning probe 4, the first tool 1, and the second tool 2 mounted on it to rotate together, positioning the positioning probe 4 above the workpiece 100 and locating the orientation of the machined tooth grooves on the workpiece 100. At this time, the positioning probe 4 detects the position, size, and other information of the workpiece 100 and transmits the detection data to the machine tool 200 control system. The control system adjusts the position of the workpiece 100 or the roughing and finishing device based on this data to achieve precise positioning of the workpiece 100, laying the foundation for subsequent processing.

[0027] On the other hand, the present invention also provides a composite gear rolling machine tool 200, which includes the above-described roughing and finishing apparatus.

[0028] In summary, compared with the prior art, the composite gear rolling machine and its roughing and finishing apparatus and method of the present invention have the following advantages and positive effects: (1) By setting up roughing tools and finishing tools to cooperate, the roughing tools bear most of the cutting amount, avoiding the finishing tools from bearing excessive cutting stress. At the same time, the roughing tools adopt an indexable insert structure, while the finishing tools adopt an integral structure. The two are adapted to different processing needs, which significantly reduces the overall wear rate of the tools, extends the service life, and reduces the tool replacement frequency and inventory costs. The roughing tools only need to be replaced with inserts, without the need for overall replacement, which reduces the number of tool replacements. At the same time, due to the extended tool service life, the number of spare tools required is reduced, which significantly reduces inventory costs. (2) The present invention realizes the rapid switching of positioning probe 4, roughing tool and finishing tool by setting turntable 5, without moving workpiece 100 or machine tool 200 body. At the same time, the slot connection structure of tool holder and clamp facilitates quick tool disassembly and assembly, reduces tool changing and parameter adjustment time, improves production efficiency and ensures machining accuracy. A high-precision angle encoder is used to detect the angle position of the rotating shaft in real time to ensure that the tool rotates synchronously. The integral structure of finishing tool further improves the tooth surface machining accuracy and effectively avoids the influence of parameter adjustment deviation on machining accuracy.

[0029] It should be noted that, unless otherwise expressly specified and limited, the term "connection" or its synonyms should be interpreted broadly in this document. For example, "connection" can be a fixed connection or a detachable connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Furthermore, expressions such as "first" and "second" are merely used to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Meanwhile, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In addition, the terms "front," "rear," "left," "right," "upper," and "lower" in this document refer to the placement states shown in the accompanying drawings.

[0030] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A roughing and finishing apparatus for a composite gear rolling machine, wherein the roughing and finishing apparatus is disposed on one side of the machine tool, characterized in that, The roughing and finishing apparatus includes a series spindle connected to the machine tool via a rotary table, a first cutting tool disposed at one end of the series spindle, a second cutting tool disposed at the other end of the series spindle, and a positioning probe disposed between the first cutting tool and the second cutting tool and connected to the series spindle, wherein: The serial spindle includes a housing, a first rotating shaft and a second rotating shaft disposed within the housing and connected to each other, and a sensor disposed between the first rotating shaft and the second rotating shaft. A drive unit is connected to the outer periphery of the first rotating shaft. A first clamp is disposed at one end of the first rotating shaft, and a transition bearing is disposed between the other end and the housing. The first clamp is connected to the first cutting tool through a first tool bar. A second clamp is disposed at one end of the second rotating shaft, and the second clamp is connected to the second cutting tool through a second tool bar. A first bearing assembly is disposed between the first rotating shaft and the housing, and a second bearing assembly is disposed between the second rotating shaft and the housing. A cable arrangement compartment is disposed on the top of the housing.

2. The roughing and finishing apparatus of the composite gear rolling machine according to claim 1, characterized in that, The first rotating shaft and the second rotating shaft are connected by a spline.

3. The roughing and finishing apparatus for the composite gear rolling machine according to claim 1, characterized in that, The cable arrangement compartment is equipped with power cable interfaces, motor temperature sensing wire interfaces, bearing temperature sensor cable interfaces, encoder cable interfaces, air seal pipe interfaces, and water cooling pipe interfaces.

4. The roughing and finishing apparatus for the composite gear rolling machine according to claim 1, characterized in that, The first clamp end face is provided with a first groove, and the first tool bar is clamped in the first groove. The second clamp end face is provided with a second groove, and the second tool bar is clamped in the second groove.

5. The roughing and finishing apparatus for the composite gear rolling machine according to claim 1, characterized in that, The first tool is a finishing tool, and the finishing tool is a one-piece tool.

6. The roughing and finishing apparatus for the composite gear rolling machine according to claim 1, characterized in that, The second tool is a roughing tool, which is an indexable insert tool.

7. The roughing and finishing apparatus for the composite gear rolling machine according to claim 1, characterized in that, The sensor is an angle encoder.

8. The roughing and finishing apparatus for the composite gear rolling machine according to claim 1, characterized in that, The drive unit is a direct drive motor.

9. A roughing and finishing method for a composite gear rolling machine, wherein the roughing and finishing method is implemented using the roughing and finishing apparatus as described in any one of claims 1 to 8, comprising: Step 1: Place the workpiece to be processed under the roughing and finishing device on one side of the machine tool; Step 2: Rotate the turntable so that the second tool is above the workpiece, start the drive unit, and perform the first machining on the workpiece to machine the basic tooth groove. The first machining will remove 80% to 90% of the total cutting amount of the workpiece. Step 3: Rotate the turntable so that the first tool is above the workpiece, start the drive unit, and perform a second machining on the workpiece. The first tool will machine a complete tooth groove based on the basic tooth groove. The second machining will remove the remaining 10% to 20% of the cutting amount of the entire workpiece.

10. A composite gear rolling machine tool, characterized in that, The composite gear rolling machine tool includes the roughing and finishing apparatus according to any one of claims 1-8.

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