Gear machining detection method

Abstract

The invention discloses a gear machining detection method, and belongs to the technical field of gear machining detection. The machining comprises machining of tooth crest chamfers, polishing of gear tooth surfaces and machining of tooth profile chamfers; the detection comprises the following steps of: detecting the sizes of each shaft and each tooth by using a micrometer, and performing three-coordinate detection on the verticality and the planeness of the end surface of the tooth part. After the technical scheme is adopted, the gear machining and detecting efficiency is improved, and the machining precision and quality are guaranteed.

Description

Technical Field

[0001] This invention relates to a method for processing and inspecting gears, belonging to the technical field of gear processing and inspection methods. Background Technology

[0002] Our company recently undertook a batch of oil pump gear processing tasks. Although the gear has a simple structure, its overall size is small and the requirements are high. The form and position tolerances and dimensional tolerances are usually in the μ level (micrometer level), which are difficult to control in terms of processing and inspection.

[0003] In terms of processing:

[0004] 1. A tooth tip chamfer of R0.1-R0.2 is required without damaging the outer chamfer. The original product was polished using a pneumatic grinder with a tungsten carbide grinding head. Because each tooth on each piece required processing, the processing time was long, requiring 10-20 minutes per piece (depending on the tooth width). Furthermore, the chamfers produced using the grinding head left grinding marks, were uneven in size, and posed a risk of denting or scratching the product. The original time quota was 300 minutes per piece, including processing the tooth profile and tooth tip. Removing the tooth profile portion, the time quota is approximately 150 minutes per piece ≈ 3.75 RMB per piece (SAP system query), which is significantly longer than expected.

[0005] 2. The gear tooth surface requires a surface roughness of Ra0.4. After the previous slow wire EDM tooth forming process, the surface roughness reaches Ra0.6, requiring a polishing process to ensure the surface roughness. Due to the small size of this gear, the polishing cloth strips on the surface of conventional polishing wheels are relatively thick, making it difficult to reach into the gear to polish the tooth surface, resulting in the surface roughness failing to meet the usage requirements.

[0006] 3. Due to limitations such as sealing requirements, the requirements for oil pump gears differ significantly from those for ordinary gears. Surface finishes are less than Ra0.8, and the tooth profiles require rounded corners of R0.1-R0.2, making machining extremely difficult. When machining the rounded corners R0.1-R0.2, the customer demands consistent uniformity. Currently, the method used is to clamp the outer diameter of the tooth tip using a tooling fixture, align the outer diameter, and then use a machining center tool holder to center and align the tooth grooves before machining. This method has the following drawbacks:

[0007] (1) The product needs to be rounded during processing. After rounding, the machining center tool holder needs to be used to insert into the tooth groove for centering and alignment. The preparation time for each part is more than 30 seconds. Each part needs to be aligned and centered, resulting in low processing efficiency.

[0008] (2) The requirements for the fillet of the gear profile of the oil pump are extremely high. After the operator finishes processing, the gear is removed for measurement and inspection. If the requirements of the drawing are not met, this processing method cannot be reworked and repaired, resulting in a long subsequent operation time for the product, or the product may be scrapped due to improper rework operation.

[0009] (3) This processing method requires finding the circle and the center on the one hand, and requires repeated operations, which is cumbersome and takes a lot of time.

[0010] Regarding testing:

[0011] 1. The current process specifies the inspection method for the product, using a digital micrometer to measure the required dimensions of each shaft, tooth width, and height. However, it does not specify more detailed requirements for the inspection environment and methods. In actual processing, due to differences in the operator, process inspector, and final inspector, there are errors at the μm level. However, our product requires μm-level accuracy, so the deviation is relatively large when reflected in the product. Currently quantifiable parameters are: 0.004mm error for different micrometer numbers, 0.002mm error for a temperature difference of 20℃ and 35℃, and 0.001-0.003mm error for different personnel (this error may be larger depending on the user's skill level). Therefore, how to improve the inspection accuracy has become an urgent technical problem to be solved.

[0012] 2. The perpendicularity requirement for the tooth end face is 0.005, and the flatness requirement is 0.003, requiring full inspection by a coordinate measuring machine (CMM). This batch consists of 40 pieces, and there are 50 similar products in the same batch, which is a relatively large quantity. Currently, the products are held in a vise. Because there is no limit to the number of positions, the products can rotate freely. During CMM inspection, it is necessary to record the data for each tooth. The calibration of each piece takes a significant amount of time, resulting in a long overall inspection time.

[0013] 3. Furthermore, conventional product tooth profile and direction inspection requires the assistance of mandrel-type fixtures. When flat holes are provided on the shafts at both ends of the gear, the flat hole φ3 is offset from the center by 1mm. During the rough machining of the inner hole in the process, after allowing for the allowance, the offset is even greater, with the hole center distance from the flat hole only 0.43mm. Currently, the smallest A-type center hole in our company has a minor diameter of 0.5mm and an opening size of φ1.06mm, which is greater than the product's flat hole offset. Therefore, it is difficult to machine the inspection mandrel and gear hobbing tooling. Due to the small size of the product and the material being 9Cr18 stainless steel, the magnetic attraction is insufficient, and it is also not possible to directly use a magnet to attract and inspect the tooth profile and direction.

[0014] Therefore, for this type of gear, how to improve processing and inspection efficiency while ensuring processing accuracy and quality has become an urgent technical problem to be solved. Summary of the Invention

[0015] The purpose of this invention is to provide a method for machining and inspecting gears. This is achieved by improving the polishing fixtures for the tooth tips and surfaces, as well as the chamfering tooling; improving the three-coordinate measuring machine (CCM) inspection limit fixture; optimizing the tooth profile inspection scheme for flat-bore gears; and standardizing the micrometer inspection process. These improvements enhance the efficiency of gear machining and inspection while ensuring machining accuracy and quality.

[0016] The technical solution of the present invention is a gear processing and inspection method, wherein the processing includes processing of tooth tip chamfering, polishing of gear tooth surface, and processing of tooth profile chamfering; the inspection includes: using a micrometer to detect the dimensions of each shaft and tooth, and performing coordinate measuring machine (CMM) detection on the perpendicularity and flatness of the tooth end face.

[0017] In the aforementioned gear processing and inspection method, the specific processing of the tooth tip chamfer is as follows: an aluminum sheet is fitted onto the shafts on both sides of the gear product to be processed, and then each side shaft is inserted into a grip handle. The radius of the aluminum sheet is 0.2mm larger than the radius of the gear product to be processed. The aluminum sheet protects the outer chamfer of the gear product to be processed. Holding the grip handle, the tooth tip chamfer of the gear product to be processed is processed using a cloth grinding wheel.

[0018] In the aforementioned gear machining and inspection method, the polishing of the gear tooth surface specifically involves: using two adjacent teeth to model and output in reverse to obtain a tooth surface polishing fixture structure, and machining the tooth surface polishing fixture. The polishing operation procedure for the tooth surface polishing fixture is as follows:

[0019] 1) Cut fine sandpaper so that it covers at least both sides of the tooth polishing fixture. Place the gear product to be processed upright on the worktable, apply diamond polishing paste to the teeth, and then place the tooth polishing fixture into the teeth that have been coated with polishing paste to ensure a gapless fit.

[0020] 2) Hold the gear product to be processed in your hand, and then pull the tooth surface polishing fixture back and forth, while maintaining a certain pressure on the tooth surface polishing fixture.

[0021] In the aforementioned gear processing and inspection method, the specific processing of the tooth profile chamfer is as follows: Multiple tooth-shaped grooves are symmetrically machined on one end face of the cylinder according to the processing procedure of the gear product to be processed, with its center as the center. The depth of the tooth-shaped grooves is less than the tooth width of the gear product to be processed. At the same time, a threaded hole is machined on the cylinder below the tooth-shaped groove. The threaded hole is connected to the inner hole of the cylinder, and the axis of the threaded hole intersects with the center line of the inner hole of the cylinder. Simultaneously, a straight edge is machined on the outer circle of the end of the cylinder with the tooth-shaped groove. Then, the tooth profile chamfer is processed: Before clamping the gear product to be processed, the cylinder is leveled by the straight edge on it. Then, the gear product to be processed is installed, and the tooth-shaped groove + straight edge is used for positioning. After one clamping and adjustment is completed, a screw is passed through the threaded hole and pressed against the shaft end of the gear product to be processed to fix it. Then, the tooth profile chamfer can be processed.

[0022] In the aforementioned gear processing and inspection method, a portion of copper is inlaid at the top of the screw; two threaded holes are symmetrically arranged.

[0023] In the aforementioned gear machining and inspection method, the specific steps of using a micrometer to inspect the dimensions of each shaft and tooth are as follows:

[0024] 1) The product to be tested should be placed in a constant temperature environment of 20-25℃ for at least 4 hours before testing and data recording are performed in the same environment;

[0025] 2) During testing, lock the digital display outside micrometer onto the base, operate with gloves, hold the product and use the digital display small head micrometer for testing. The holding time of the product for a single measurement should be ≤30 seconds. When testing with the micrometer, after the anvil and micrometer screw are in contact with the end face of the product, rotate the knob 2-3 times and read the data.

[0026] Tooth width inspection: Full inspection of tooth position, first inspect the outer side of each tooth, then inspect the inner side;

[0027] Diameter inspection of each cylindrical segment at both ends of the tooth: Inspection should be carried out in at least two segments, upper and lower, with two points inspected for each segment. After inspecting one point, rotate 90° and inspect the second point.

[0028] Mark the points where the parallelism is out of tolerance.

[0029] In the aforementioned gear processing and inspection method, the three-coordinate measurement of the perpendicularity and flatness of the tooth end face is specifically performed as follows: a limiting fixture is used in conjunction with a vise to limit and fix the product to be inspected. The limiting fixture includes an L-shaped limiting plate, with a locating pin inserted vertically along one side of the L-shaped limiting plate. Locking nuts are threaded onto the locating pins on both sides of the L-shaped limiting plate. The product is held in place with the rotating end of the vise facing inward. A magnet is used to attract the back of the vise, with the end face of the magnet protruding above the surface of the vise. The limiting device is placed on the surface of the vise and simultaneously aligned with the vise and the magnet. The locating pin is rotated to press against the tooth of the product to be inspected. Three-coordinate measurement is performed, programming is completed, and the first inspection and debugging are completed. After the inspection is completed, only the vise handle needs to be rotated to remove and reinsert the product.

[0030] In the aforementioned gear processing and inspection method, the inspection further includes inspecting the gear tooth profile of the disc gear whose inner hole is a flat hole. Specifically, an inspection fixture is fabricated, comprising a threaded base, a threaded cylinder vertically disposed at the center of the surface of the threaded base, a washer, a nut, and a positioning cylinder. The threaded base, washer, nut, and positioning cylinder are all made of non-magnetic materials. The diameter of the threaded cylinder is smaller than the radial width of the flat hole. The inner hole of the positioning cylinder maintains a small clearance fit with the disc gear. Then, the inspection begins.

[0031] (1) Fit the disc gear to be tested onto the threaded cylinder and lock it in place with washers and nuts.

[0032] (2) Place the two magnets on the testing equipment platform. The two magnets should be at the same height and higher than the bottom pin of the equipment. Place the magnetic material plate on the upper surface of the two magnets, and then place the assembled product components on the magnetic material plate, and place them roughly in the center of the testing equipment platform.

[0033] (3) Put the positioning cylinder on the product component, place it against the flat threaded base, lower the pin on the testing equipment until it is locked in the positioning cylinder, turn on the magnetic switch, raise the top center, and complete the coarse positioning.

[0034] (4) Use a lever dial indicator to correct the lower end of the positioning cylinder to run out less than the set threshold, and then remove the positioning cylinder and the lever dial indicator;

[0035] (5) Start the test. During the test, only the right tooth surface is tested due to magnetic interference. After completion, remove the components, turn the product around, and repeat the above steps to test the left tooth surface.

[0036] In the aforementioned gear processing and inspection method, the inspection further includes inspecting the tooth direction of the gear with a flat inner hole in the disc gear. At this time, a protrusion is provided on the surface of the threaded base, and the threaded cylinder is provided on the protrusion.

[0037] In the aforementioned gear processing and inspection method, a runout groove is provided at the bottom of the threaded cylinder and the threaded base or protrusion connection.

[0038] The beneficial effects of this invention are as follows: Compared with the prior art, this invention, by adopting the above-described technical solution, improves the efficiency of gear processing and inspection, while ensuring processing accuracy and quality. Specifically, this is reflected in the following aspects:

[0039] (1) By making a tooth top polishing fixture, the outer circle of the product is protected by chamfering, so as not to scratch the product. At the same time, the handle is added for gripping, and the tooth top is processed by a cloth grinding wheel, thus realizing the processing of this polishing process. The handle and the easily worn aluminum sheet are made into a separate shape, which reduces the manufacturing cost. Currently, it takes 1-2 minutes to polish one product, which is more than 10 times shorter. The time quota is 120 minutes / piece, including polishing end face, rust removal, tooth top rounding, etc. Only the tooth top polishing and rounding part is calculated to be about 40 minutes / piece ≈ 1 yuan / piece (SAP system query). The time saved by each product in the tooth top rounding step is 73%.

[0040] (2) The specific requirements for the control of inspection personnel, environment, methods and tools are clearly defined in the gear micrometer inspection method, thereby reducing non-machining errors generated during inspection.

[0041] (3) Polish the tooth surface using a tooth surface polishing tool with the same structure as the gear. Since the tooth surface polishing tool has the same processing procedure as the gear tooth, it is a surface contact when in contact. According to the test, it takes 20-30 seconds to process a single tooth, which is at least 200% more efficient than the original file. At the same time, this method can also be applied to internal teeth or small module external teeth and other situations where it is difficult to polish the tooth surface and tooth root.

[0042] (4) Make a limiting fixture by using the existing tools in the metrology room as much as possible. It consists of a limiting block, a positioning pin and a nut. After the test is completed, you only need to rotate the vise handle to take the product out and put it back in, thus saving the test time.

[0043] (5) By making a flat hole gear tooth profile detection fixture, the rapid detection of flat hole gear tooth profile can be realized. The data detected by using the fixture is consistent with the data detected by directly using the gear hobbing tool, which verifies the feasibility of the fixture.

[0044] (6) By making a tooth profile chamfering fixture, the product clamping time is about 7 seconds, which improves production efficiency by more than 100%. The fixture can be repeatedly positioned and clamped. If a problem occurs after the product is processed once, the fixture can be used for rework, avoiding the product scrapping caused by rework in other ways, and ensuring a 100% product qualification rate. The fixture solves the problem of chamfering R0.1-R0.2 fillet on the tooth profile of oil pump gears. Attached Figure Description

[0045] Figure 1 This is a structural diagram of a tooth tip chamfering tool;

[0046] Figure 2 A schematic diagram of the structure for installing a gear into a tooth tip chamfering fixture;

[0047] Figure 3 This is a schematic diagram of the gear structure to be processed;

[0048] Figure 4 Images showing the process of machining tooth chamfers using a tooth chamfering fixture;

[0049] Figure 5 A schematic diagram of the tooth surface polishing fixture;

[0050] Figure 6 Images showing the polishing of tooth surfaces using a tooth surface polishing fixture;

[0051] Figure 7 A schematic diagram of the tooling for chamfering tooth profiles;

[0052] Figure 8 This is a top view of the cylindrical structure.

[0053] Figure 9 Image showing a gear placed on a tooth profile chamfering fixture;

[0054] Figure 10 This is a schematic diagram of the structure of a coordinate measuring machine tool.

[0055] Figure 11 This is a schematic diagram of the structure of a coordinate measuring machine limit fixture;

[0056] Figure 12 Images showing the use of a coordinate measuring machine (CMM) limit fixture.

[0057] Figure 13 A schematic diagram of a flat-bore gear being placed in a tooth profile inspection fixture;

[0058] Figure 14 A schematic diagram of a threaded base structure with protrusions;

[0059] Figure 15 A schematic diagram of a gear structure with a flat bore;

[0060] Figure 16 Images showing the product coarse positioning achieved using a tooth profile inspection fixture;

[0061] Figure 17 Images showing the process of using a tooth profile inspection fixture to correct the runout of the outer circle;

[0062] Figure 18 Images showing the use of toothed inspection fixtures for product inspection;

[0063] Figure 19 Data obtained from normal use of the mandrel during testing;

[0064] Figure 20 The data is obtained by using the tooth profile detection tool of the present invention.

[0065] Reference numerals: 1-Aluminum sheet, 2-Holding handle, 3-Gear polishing fixture, 4-Cylinder body, 5-Gear countersunk groove, 6-Threaded hole, 7-Straight edge, 8-Screw, 9-Visor, 10-L-shaped limit plate, 11-Positioning pin, 12-Locking nut, 13-Magnet, 14-Threaded base, 15-Threaded cylinder, 16-Washer, 17-Nut, 18-Positioning cylinder, 19-Protrusion, 20-Overrun groove. Detailed Implementation

[0066] The present invention will be further described below with reference to the accompanying drawings and embodiments, but this should not be construed as limiting the present invention.

[0067] An embodiment of the present invention: a gear machining and inspection method, wherein the machining includes machining of tooth tip chamfering, polishing of gear tooth surface, and machining of tooth profile chamfering; the inspection includes: using a micrometer to inspect the dimensions of each shaft and tooth, and performing coordinate measuring machine (CMM) inspection on the perpendicularity and flatness of the tooth end face.

[0068] The specific process for chamfering the gear teeth is as follows: An aluminum sheet 1 is fitted onto the shafts on both sides of the gear product to be processed. Then, each shaft is inserted into a handle 2. The radius of the aluminum sheet 1 is 0.2 mm larger than the radius of the gear product to be processed. The aluminum sheet 1 protects the outer chamfer of the gear product. Since the gear product has already been finely ground during this polishing process, using alloy steel or stainless steel for the sheet material would cause wear. Holding the handle 2, a cloth abrasive wheel is used to chamfer the gear teeth.

[0069] Using this polishing fixture, the outer chamfer of the product can be protected by an aluminum sheet 1, which is made of aluminum and will not scratch the product. A handle 2 is added for gripping, and a cloth abrasive wheel is used to process the tooth tips, thus completing the polishing process. Making the handle 2 and the easily worn part (aluminum sheet 1) separate reduces manufacturing costs. Currently, processing one product takes 1-2 minutes, a reduction of more than 10 times. The time quota is 120 minutes / piece, including polishing the end face, rust removal, and tooth tip rounding. Calculating only the tooth tip polishing and rounding part, it takes approximately 40 minutes / piece ≈ 1 yuan / piece (SAP system query). Each product saves 73% of the time in the tooth tip rounding step.

[0070] The polishing of the gear tooth surface is specifically as follows: A tooth surface polishing fixture 3 structure is obtained by modeling two adjacent teeth in reverse and outputting the result. The tooth surface polishing fixture 3 is then machined. The polishing operation procedure for the tooth surface polishing fixture 3 is as follows:

[0071] 1) Cut fine sandpaper so that it covers at least two sides of the tooth surface polishing fixture 3. Place the gear product to be processed upright on the worktable, apply diamond polishing paste to the teeth, and then place the tooth surface polishing fixture 3 into the teeth that have been coated with polishing paste to ensure a gapless fit.

[0072] 2) Hold the gear product to be processed in your hand, and then pull the tooth surface polishing fixture 3 back and forth, while maintaining a certain pressure on the tooth surface polishing fixture 3.

[0073] After processing, the completeness of polishing can be observed from the sandpaper marks and product marks. The tooth surface can basically achieve the required roughness in one pass. Tests show that processing a single tooth takes 20-30 seconds, which is at least 200% more efficient than using a file. This method can also be applied to internal teeth or small-module external teeth where it is difficult to polish the tooth surface and root.

[0074] The specific processing of the tooth profile chamfering is as follows: On one end face of the cylinder 4, multiple tooth-shaped grooves 5 are symmetrically milled with the center of the groove as the center according to the processing procedure of the gear product to be processed. The depth of the tooth-shaped grooves 5 is less than the tooth width of the gear product to be processed, so that part of the gear is exposed after it is installed, so that the tooth profile can be chamfered on the exposed part. At the same time, a threaded hole 6 is machined on the cylinder 4 below the tooth-shaped grooves 5. The threaded hole 6 is connected to the inner hole of the cylinder 4, and the axis of the threaded hole 6 intersects the center line of the inner hole of the cylinder 4. At the same time, a straight edge 7 is machined on the outer circle of the end of the cylinder 4 where the tooth-shaped grooves 5 are machined. The straight edge 7 is aligned with the inner tooth-shaped grooves 5, so that the gear is automatically positioned after it is installed in the tooling.

[0075] Then, the tooth profile chamfering is performed: Before clamping the gear product to be processed, the cylinder 4 is leveled by the straight edge 7 on it, and then the gear product to be processed is installed. The tooth profile groove 5 + straight edge 7 is used for positioning. After the clamping and debugging are completed, the screw 8 is passed through the threaded hole 6 and then pressed against the shaft end of the gear product to be processed to fix it. Then the tooth profile chamfering can be performed.

[0076] The top of the screw 8 is inlaid with a portion of copper. Copper is soft and will not leave marks after its top abuts against the cylindrical surface of the gear side, thus protecting the product from damage. The threaded holes 6 are symmetrically arranged in two places, through which two screws 8 are inserted to secure the gear.

[0077] The specific steps for using a micrometer to inspect the dimensions of each shaft and tooth are as follows:

[0078] The product to be tested should be placed in a constant temperature environment of 20-25℃ for at least 4 hours before testing and data recording are performed in this environment. This temperature range can reduce testing errors caused by temperature changes.

[0079] During testing, lock the digital outside micrometer onto the base, operate with gloves, hold the product by hand and use the digital small-head micrometer for testing. The time for holding the product for a single measurement should be ≤30 seconds. When testing with the micrometer, after the anvil and micrometer screw are in contact with the end face of the product, rotate the knob 2-3 times and read the data.

[0080] Tooth width inspection: Full inspection of tooth position, first inspect the outer side of each tooth, then inspect the inner side;

[0081] Diameter inspection of each cylindrical segment at both ends of the tooth: Inspection should be carried out in at least two segments, upper and lower, with two points inspected for each segment. After inspecting one point, rotate 90° and inspect the second point.

[0082] Mark the points where the parallelism is out of tolerance.

[0083] The three-coordinate measurement of the perpendicularity and flatness of the tooth end face is specifically performed as follows: A limiting clamp is used in conjunction with a vise 9 to limit and fix the product to be tested. The limiting clamp includes an L-shaped limiting plate 10, with a positioning pin 11 vertically inserted on one side of the L-shaped limiting plate 10. Locking nuts 12 are threaded onto the positioning pins 11 on both sides of the L-shaped limiting plate 10. The vise 9 is used to clamp the product with its rotating end facing inward. A magnet 13 is used to attract the back of the vise 9, with the end face of the magnet 13 protruding above the surface of the vise 9. The limiting device is placed on the surface of the vise 9 and simultaneously aligned with the vise 9 and the magnet 13. The switch of the magnet 13 is turned on, and the L-shaped limiting plate 10 and the vise 9 are attracted and fixed by the magnet 13. The positioning pin 11 is rotated to press against the tooth of the product to be tested. Then, the locking nuts 12 are tightened to fix the positioning pin 11. Three-coordinate measurement and programming are performed to complete the first inspection and debugging. After the test is completed, only the handle of the vise 9 needs to be rotated to remove and put the product back in. Thanks to the positioning pin 11, product rotation can be prevented during the inspection process.

[0084] The inspection also includes testing the tooth profile of gears with flat inner holes in the disc gear. Specifically, a testing fixture is fabricated, comprising a threaded base 14, a threaded cylinder 15 vertically positioned at the center of the surface of the threaded base 14, a washer 16, a nut 17, and a positioning cylinder 18. The threaded base 14, washer 16, nut 17, and positioning cylinder 18 are all made of non-magnetic materials to avoid the influence of magnetic attraction during subsequent testing. The diameter of the threaded cylinder 15 is smaller than the radial width of the flat hole to facilitate gear insertion. The inner hole of the positioning cylinder 18 maintains a small clearance fit with the disc gear, and then the inspection begins.

[0085] (1) The disc gear to be tested is sleeved on the threaded cylinder 15 and locked in place by washer 16 and nut 17;

[0086] (2) Place the two magnets on the testing equipment platform. The two magnets should be at the same height and higher than the bottom pin of the equipment. Place the magnetic material plate on the upper surface of the two magnets, and then place the assembled product components on the magnetic material plate, and place them roughly in the center of the testing equipment platform.

[0087] (3) Place the positioning cylinder 18 on the product component and place it against the flat threaded base 14. Lower the pin on the testing equipment until it is locked in the positioning cylinder 18. Turn on the magnetic switch and raise the top center to complete the coarse positioning.

[0088] (4) Use a lever micrometer to correct the lower end of the positioning cylinder 18 to run out less than the set threshold, and then remove the positioning cylinder 18 and the lever micrometer.

[0089] (5) Start the test. During the test, only the right tooth surface is tested due to magnetic interference. After completion, remove the components, turn the product around, and repeat the above steps to test the left tooth surface.

[0090] The current solution of directly setting the threaded cylinder 15 on the threaded base 14 can only detect the tooth profile because the base of the threaded base 14 is large and interferes with the probe of the detection equipment. Therefore, the structure of the threaded base 14 has been improved. Now, a protrusion 19 is set on the surface of the threaded base 14, and the threaded cylinder 15 is set on the protrusion 19 to realize the detection of the tooth direction.

[0091] A runout groove 20 is provided at the bottom of the threaded cylinder 15 and the connection part between the threaded base 14 or the protrusion 19 to ensure that the bottom surface of the gear fits in contact with the surface of the threaded base 14 or the protrusion 19.

[0092] Combination Figure 19 and Figure 20 It can be seen that the data detected using this tool ( Figure 20 ) and data directly measured using gear hobbing fixtures ( Figure 19 The results showed a good match and consistency, verifying the feasibility of the tooling and method.

Claims

1. A method for machining and inspecting gears, characterized in that: The processing includes tooth tip chamfering, gear tooth surface polishing, and tooth profile chamfering; the inspection includes: using a micrometer to inspect the dimensions of each shaft and tooth, and performing coordinate measuring machine (CMM) inspection on the perpendicularity and flatness of the tooth end face.

2. The gear machining and inspection method according to claim 1, characterized in that: The specific processing of the tooth tip chamfer is as follows: an aluminum sheet (1) is attached to the shafts on both sides of the gear product to be processed, and then the shafts on both sides are inserted into a grip handle (2). The radius of the aluminum sheet (1) is 0.2 mm larger than the radius of the gear product to be processed. The outer chamfer of the gear product to be processed is protected by the aluminum sheet (1). Hold the grip handle (2) and use a cloth grinding wheel to process the tooth tip chamfer of the gear product to be processed.

3. The gear machining and inspection method according to claim 1, characterized in that: The polishing of the gear tooth surface is specifically as follows: using two adjacent teeth to model and output in reverse to obtain the tooth surface polishing fixture (3) structure, and machining to obtain the tooth surface polishing fixture (3). The polishing operation procedure of the tooth surface polishing fixture (3) is as follows: 1) Cut fine sandpaper so that it covers at least both sides of the tooth surface polishing fixture (3). Place the gear product to be processed upright on the worktable, apply diamond polishing paste to the teeth, and then place the tooth surface polishing fixture (3) into the teeth that have been coated with polishing paste to ensure a seamless fit. 2) Hold the gear product to be processed in your hand, and then pull the tooth surface polishing fixture (3) back and forth, while maintaining a certain pressure on the tooth surface polishing fixture (3).

4. The gear machining and inspection method according to claim 1, characterized in that: The specific processing of the tooth profile chamfer is as follows: On one end face of the cylinder (4), multiple tooth-shaped grooves (5) are symmetrically processed with the center of the groove as the center according to the processing procedure of the gear product to be processed. The depth of the tooth-shaped grooves (5) is less than the tooth width of the gear product to be processed. At the same time, a threaded hole (6) is processed on the cylinder (4) below the tooth-shaped grooves (5). The threaded hole (6) is connected to the inner hole of the cylinder (4), and the axis of the threaded hole (6) intersects with the center line of the inner hole of the cylinder (4). A straight edge (7) is machined on the outer circle of one end of the toothed groove (5); then the tooth profile chamfering is performed: before clamping the gear product to be processed, the cylinder (4) is leveled by the straight edge (7) on it, and then the gear product to be processed is installed. The toothed groove (5) + straight edge (7) is used for positioning. After the clamping and debugging is completed, the screw (8) is passed through the threaded hole (6) and then pressed against the shaft end of the gear product to be processed to fix it. Then the tooth profile chamfering can be performed.

5. The gear machining and inspection method according to claim 4, characterized in that: A portion of copper is inlaid at the top of the screw (8); two threaded holes (6) are symmetrically arranged.

6. The gear machining and inspection method according to claim 1, characterized in that: The specific steps for using a micrometer to inspect the dimensions of each shaft and tooth are as follows: The product to be tested should be placed in a constant temperature environment of 20-25℃ for at least 4 hours before testing and data recording are performed in the same environment. During testing, lock the digital outside micrometer onto the base, operate with gloves, hold the product by hand and use the digital small-head micrometer for testing. The time for holding the product for a single measurement should be ≤30 seconds. When testing with the micrometer, after the anvil and micrometer screw are in contact with the end face of the product, rotate the knob 2-3 times and read the data. Tooth width inspection: Full inspection of tooth position, first inspect the outer side of each tooth, then inspect the inner side; Diameter inspection of each cylindrical segment at both ends of the tooth: Inspection should be carried out in at least two segments, upper and lower, with two points inspected for each segment. After inspecting one point, rotate 90° and inspect the second point. Mark the points where the parallelism is out of tolerance.

7. The gear machining and inspection method according to claim 1, characterized in that: The three-coordinate measurement of the perpendicularity and flatness of the tooth end face is specifically performed as follows: a limiting clamp is used in conjunction with a vise (9) to limit and fix the product to be tested. The limiting clamp includes an L-shaped limiting plate (10). A positioning pin (11) is inserted vertically on one side of the L-shaped limiting plate (10). Locking nuts (12) are threaded onto the positioning pins (11) on both sides of the L-shaped limiting plate (10). The product is clamped with the rotating end of the vise (9) facing inward. The back of the vise (9) is attracted by a magnet (13). The end face of the magnet (13) needs to be higher than the surface of the vise (9). The limiting device is placed on the surface of the vise (9) and simultaneously against the vise (9) and the magnet (13). The positioning pin (11) is rotated to press against the tooth of the product to be tested. The three-coordinate measurement is performed, the programming is completed, and the first inspection debugging is completed. After the test is completed, only the handle of the vise (9) needs to be rotated to complete the product removal and re-placement.

8. The gear machining and inspection method according to claim 1, characterized in that: The inspection also includes inspecting the tooth profile of the gear with a flat inner hole in the disc gear. Specifically, an inspection fixture is made, which includes a threaded base (14), a threaded cylinder (15) vertically disposed at the center of the surface of the threaded base (14), a washer (16), a nut (17), and a positioning cylinder (18). The threaded base (14), washer (16), nut (17), and positioning cylinder (18) are all made of non-magnetic materials. The diameter of the threaded cylinder (15) is smaller than the radial width of the flat hole. The inner hole of the positioning cylinder (18) maintains a small clearance fit with the disc gear. Then the inspection begins. (1) The disc gear to be tested is fitted onto the threaded cylinder (15) and locked in place by washers (16) and nuts (17). (2) Place the two magnets on the testing equipment platform. The two magnets should be at the same height and higher than the bottom pin of the equipment. Place the magnetic material plate on the upper surface of the two magnets, and then place the assembled product components on the magnetic material plate, and place them roughly in the center of the testing equipment platform. (3) Place the positioning cylinder (18) on the product component, place it against the flat threaded base (14), lower the pin on the testing equipment until it is locked to the positioning cylinder (18), turn on the magnetic switch, raise the top center, and complete the coarse positioning; (4) Use a lever micrometer to calibrate the lower end of the positioning cylinder (18) so that the jump is less than the set threshold, and then remove the positioning cylinder (18) and the lever micrometer. (5) Start the test. During the test, only the right tooth surface is tested due to magnetic interference. After completion, remove the components, turn the product around, and repeat the above steps to test the left tooth surface.

9. A gear machining and inspection method according to claim 8, characterized in that: The detection also includes detecting the tooth direction of the gear with a flat inner hole in the disc gear. At this time, a protrusion (19) is provided on the surface of the threaded base (14), and the threaded cylinder (15) is provided on the protrusion (19).

10. A gear machining and inspection method according to claim 9, characterized in that: The bottom of the threaded cylinder (15) is provided with a runout groove (20) at the connection between the threaded base (14) or the protrusion (19).

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