Intelligent feeding control system for numerical control meshing cold extrusion reverse tapered teeth
By combining parameter pre-fitting, flexible clamping, and segmented feed strategies, the accuracy and efficiency issues of the CNC meshing cold extrusion reverse bevel gear machining system were solved, achieving high-precision and low-cost reverse bevel gear machining.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- BAOJI DONGYANG MASCH MFG CO LTD
- Filing Date
- 2026-02-02
- Publication Date
- 2026-04-28
AI Technical Summary
Existing CNC meshing cold extrusion bevel gear machining systems suffer from problems such as fixed process parameters, unreasonable clamping structures, rough control of the machining process, and reliance on experience for extrusion wheel maintenance. These issues make it difficult to improve machining accuracy and efficiency, and also result in high costs.
The system employs a parameter pre-adaptation module to dynamically correct process parameters, a flexible clamping module to reduce deformation during thin-walled part clamping, a segmented feeding strategy combined with real-time monitoring and control to ensure accuracy and quality screening, and a precise maintenance module for extrusion roller life management to improve equipment stability and economy.
It enables high-precision machining of workpieces made of different materials, reduces the deformation rate of thin-walled parts, reduces inspection costs and maintenance expenses, and improves machining stability and economy.
Smart Images
Figure CN121927979A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of gear cold extrusion processing technology, specifically to a CNC meshing cold extrusion reverse bevel gear intelligent feed control system. Background Technology
[0002] As a core functional structure of automotive synchronizers, the inverted bevel gear directly determines the shift response speed and transmission stability of the synchronizer, based on its tooth profile accuracy, roundness error, and surface integrity. It plays a crucial role in preventing accidental gear disengagement during vehicle operation and ensuring driving safety. With the automotive industry's continuously increasing demands for precision in transmission system components, the machining of inverted bevel gears must meet technical specifications such as a roundness error ≤0.01mm and a tooth profile accuracy of IT5 level. Traditional cutting processes, due to the disruption of metal fiber continuity during material removal, easily lead to decreased tooth surface strength and difficulty in maintaining stable machining accuracy. In contrast, CNC meshing cold extrusion technology, with its advantages of chipless machining, high material utilization, and continuous metal fiber on the tooth surface, has become the mainstream technology for high-precision machining of inverted bevel gears.
[0003] Existing CNC meshing cold extrusion bevel gear machining systems suffer from numerous technical defects in practical applications, hindering improvements in machining accuracy and production efficiency. Firstly, the process parameters are rigidly set. Existing systems often use fixed process parameters preset for a single material, failing to dynamically adjust key parameters such as extrusion pressure and feed rate based on the actual hardness deviation of the workpiece and changes in the machining environment temperature. This results in significant differences in tooth filling accuracy after machining workpieces of different materials, easily leading to problems such as tooth root interference or insufficient tooth tip filling, and large fluctuations in the accuracy compliance rate for multi-material workpieces. Secondly, the clamping structure design is unreasonable. Traditional systems generally use a three-point clamping rigid clamping method. When clamping thin-walled tooth sleeves with a wall thickness of 1-3mm, localized clamping stress concentration easily causes elliptical deformation of the workpiece, resulting in excessive coaxiality. The high error rate directly affects the subsequent tooth forming accuracy; thirdly, the processing control is rough, lacking differentiated feed control strategies for different stages of inverted conical tooth forming. The traditional uniform feed mode cannot take into account both the positioning efficiency in the early stage of processing and the tooth shape finishing accuracy in the later stage of processing; at the same time, real-time monitoring is limited to extrusion pressure overload protection and cannot predict the roundness error of the workpiece in advance. Defective parts need to be removed after offline inspection, which increases the inspection cost and production cycle; in addition, the extrusion roller maintenance relies on manual experience judgment and has not established a quantitative correlation between wear and processing accuracy. Excessive wear of the extrusion roller can easily lead to batch workpiece accuracy deviation, resulting in high equipment operation and maintenance costs. Summary of the Invention
[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a CNC meshing cold extrusion inverted bevel gear intelligent feed control system. This system dynamically corrects process parameters through a parameter pre-adaptation module to adapt to the needs of workpieces with different materials; a flexible clamping module reduces clamping deformation of thin-walled parts and improves machining accuracy. The system adopts a segmented feed strategy, combined with roundness error prediction by a real-time monitoring and control module, to ensure machining accuracy and quality screening; at the same time, the extrusion roller life management module accurately calculates wear, prompts maintenance, extends equipment life, reduces operating costs, and comprehensively improves machining stability and economy.
[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a CNC meshing cold extrusion reverse bevel gear intelligent feed control system, the system comprising: Parameter pre-adaptation module: Based on the material of the workpiece to be processed, the reference process parameters are retrieved from the parameter library, the surface hardness of the workpiece and the temperature of the processing environment are detected to obtain deviation data, and the reference process parameters are corrected by combining the deviation data and using the logic corresponding to the dynamic adaptation formula of the extrusion force, so as to obtain the adapted process parameters including the adapted extrusion force, the adapted feed speed and the adapted spindle speed. Flexible clamping module: Adjust the arc-shaped jaws of the flexible ring clamp to fit the outer circle of the workpiece, adjust the clamping force of the jaws on the workpiece according to the parameter pre-adaptation module's adaptation extrusion force according to the clamping force-extrusion force correlation logic, and perform axial positioning of the workpiece through the positioning pins of the clamp base, and detect the coaxiality and initial roundness of the workpiece after clamping. CNC extrusion feed module: Initialize the spindle, radial feed axis, and extrusion wheel axis; drive the spindle and extrusion wheel axis to rotate synchronously according to the meshing transmission ratio; drive the radial feed axis to drive the extrusion wheel to feed gradually according to the segmented feed strategy and the appropriate feed speed and apply appropriate extrusion force; after the extrusion wheel feed displacement reaches the specified tooth width and the extrusion force stabilizes for the specified time, stop the movement of each axis and complete the inverted conical tooth extrusion forming. Real-time monitoring and control module: Real-time acquisition of extrusion pressure, feed displacement, and rotation angle data are compared with the adaptive parameter thresholds. When the threshold is exceeded, overload protection is executed. The logic corresponding to the roundness error prediction formula is used to mark unqualified workpieces and trigger rejection. Processing data is recorded. Extrusion Roller Life Management Module: The extrusion roller is calibrated for tooth profile accuracy. Based on the appropriate process parameters and the number of workpieces processed, the cumulative wear of the extrusion roller is calculated using the logic corresponding to the extrusion roller wear calculation formula. When the wear reaches the specified threshold, the module prompts for repair or replacement. After repair, the extrusion roller is recalibrated.
[0006] Furthermore, the dynamic adaptation calculation formula for extrusion pressure in the parameter pre-adaptation module is as follows: ,in, To adapt to the extrusion pressure; The extrusion pressure is based on the material. This refers to the material property coefficient; This refers to the workpiece hardness deviation. This represents the material hardness threshold. Temperature coefficient; This refers to temperature deviation.
[0007] Furthermore, the formula for calculating the clamping force-extrusion force relationship in the flexible clamping module is as follows: ,in, To adjust the clamping force; Clamping force is based on wall thickness; To accommodate the difference between the extrusion pressure and the reference extrusion pressure; The reference extrusion pressure; This refers to the deviation in workpiece wall thickness. This is the baseline value for wall thickness.
[0008] Furthermore, the segmented feeding strategy in the CNC extrusion feed module is as follows: In the initial feeding stage, the goal is to quickly approach the workpiece, and the radial feed axis is controlled to drive the extrusion roller to move at a rate higher than the appropriate feed speed; in the middle feeding stage, the goal is to ensure stable tooth profile formation, and the radial feed axis is controlled to drive the extrusion roller to maintain an appropriate feed speed; in the final feeding stage, the goal is to optimize the tooth profile finishing accuracy, and the radial feed axis is controlled to drive the extrusion roller to move at a rate lower than the appropriate feed speed; when the spindle and the extrusion roller shaft rotate synchronously, the speed deviation is corrected in real time through the electronic gearbox to ensure that the synchronization accuracy of the rotation angle of the two meets the requirements for inverted bevel tooth formation.
[0009] Furthermore, the fixture base of the flexible clamping module has a built-in temperature compensation shim; the temperature compensation shim is made of a low expansion coefficient alloy, and the thermal expansion coefficient of this alloy meets the deformation compensation requirements of the fixture base; when the processing environment temperature deviates from the room temperature reference, the thickness of the temperature compensation shim is adjusted to compensate for the deformation of the fixture base caused by the temperature change.
[0010] Furthermore, the extrusion roller shaft of the CNC extrusion feed module is equipped with an independent servo drive unit; the servo drive unit monitors the rotational torque of the extrusion roller shaft in real time, and when the rotational torque exceeds a specified multiple of the rated torque of the extrusion roller shaft, it reduces the speed of the extrusion roller shaft to a specified ratio of the reference speed; when the rotational torque falls back to within a specified multiple of the rated torque, it controls the extrusion roller shaft to return to the original speed.
[0011] Furthermore, the overload protection of the real-time monitoring and control module is implemented in two levels: Level 1 overload occurs when the real-time extrusion pressure reaches a first specified ratio of the appropriate extrusion pressure, controlling the radial feed axis to reduce the feed speed; Level 2 overload occurs when the real-time extrusion pressure exceeds a second specified ratio of the appropriate extrusion pressure, controlling the radial feed axis to pause feeding and maintain the current position, and triggering an emergency stop if the extrusion pressure does not drop; wherein, the second specified ratio is greater than the first specified ratio.
[0012] Furthermore, the roundness error prediction calculation formula in the real-time monitoring and control module is as follows: ,in, To predict roundness error; The roundness error is based on the material reference. This refers to the real-time extrusion pressure deviation. To adapt to the extrusion pressure; This refers to the real-time feed rate deviation. To adapt to the feed rate; , To influence the weights.
[0013] Furthermore, the formula for calculating extrusion roller wear in the extrusion roller life management module is as follows: ,in, This represents the cumulative wear and tear. The wear coefficient is the unit wear factor. The number of workpieces processed; To adapt to the extrusion pressure; The reference extrusion pressure is used; the calibration standard for the extrusion wheel tooth profile accuracy is: the tooth pitch deviation and the radial runout of the tooth ring both meet the requirements for the forming accuracy of the inverted conical teeth.
[0014] Compared with existing technologies, this CNC meshing cold extrusion reverse bevel gear intelligent feed control system has the following advantages: I. This invention overcomes the limitations of traditional cold extrusion systems' "fixed parameter processing" and "rigid clamping" by combining the dynamic adaptation logic of the extrusion pressure in the parameter pre-adaptation module with the clamping force-extrusion force correlation control in the flexible clamping module. The parameter pre-adaptation module dynamically corrects the extrusion pressure and feed rate based on workpiece hardness and temperature deviation, adapting to the processing requirements of workpieces of different materials and avoiding problems such as insufficient tooth filling or interference caused by differences in material properties. The flexible clamping module reduces local stress when clamping thin-walled toothed sets by dynamically adjusting the contact of the arc-shaped jaw surface and the clamping force, effectively controlling the coaxiality and initial roundness deviation of the workpiece, significantly reducing the deformation rate of thin-walled parts, and improving the consistency of processing accuracy for multi-material workpieces.
[0015] II. This invention optimizes the entire process of reverse bevel gear machining—from precision assurance to quality screening to equipment maintenance—through a segmented feed strategy in the CNC extrusion feed module, a roundness error prediction logic in the real-time monitoring and control module, and wear calculation in the extrusion roller life management module. Segmented feed differentiates the feed rate according to the forming stage, balancing processing efficiency and tooth profile finishing accuracy; roundness error prediction can identify defective workpieces in advance, reducing subsequent inspection costs; and extrusion roller wear calculation accurately indicates maintenance opportunities, avoiding batch precision deviations caused by excessive extrusion roller wear, extending extrusion roller life, reducing equipment maintenance costs and defect rate, and improving overall processing stability and economy.
[0016] 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 study, or may be learned from the practice of the invention. Attached Figure Description
[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.
[0018] Figure 1 Flowchart of the operation of the intelligent feed control system for CNC meshing cold extrusion bevel gears; Figure 2 This is a module logic framework diagram of the intelligent feed control system for CNC meshing cold extrusion reverse bevel gears. Detailed Implementation
[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.
[0020] Example 1: Machining of automotive synchronizer outer gear sleeve The specific process is as follows: Figure 1 As shown: The pre-adaptation module is activated. Based on the 20CrMnTi material of the automotive synchronizer outer gear sleeve to be processed, the corresponding baseline process parameters are retrieved from the system. After obtaining deviation data by detecting the workpiece surface hardness and the processing environment temperature through sensors, the baseline process parameters are corrected using the logic corresponding to the dynamic adaptation formula of the extrusion pressure. Finally, the adapted process parameters consisting of adapted extrusion pressure, adapted feed speed, and adapted spindle speed are generated, and the parameters are simultaneously transmitted to the subsequent modules. The dynamic adaptation calculation formula for extrusion pressure is as follows: ,in, To adapt to the extrusion pressure; The extrusion pressure is based on the material. This refers to the material property coefficient; This refers to the workpiece hardness deviation. This represents the material hardness threshold. Temperature coefficient; This refers to temperature deviation.
[0021] Run the flexible clamping module and adjust the arc-shaped jaws of the flexible ring-shaped clamp to ensure that the inner side of the jaws completely fits the outer circle of the outer toothed sleeve; based on the adaptive extrusion force output by the parameter pre-adaptation module, adjust the clamping force of the jaws according to the clamping force-extrusion force correlation logic. The clamping force-extrusion force correlation calculation formula is as follows: ,in, To adjust the clamping force; Clamping force is based on wall thickness; To accommodate the difference between the extrusion pressure and the reference extrusion pressure; The reference extrusion pressure; This refers to the deviation in workpiece wall thickness. The wall thickness is the reference value; the workpiece is axially positioned by the positioning pin of the fixture base. After positioning, the coaxiality and initial roundness of the workpiece after clamping are checked. After confirming that it is qualified, a ready signal is sent to the CNC extrusion feed module.
[0022] Activate the CNC extrusion feed module to initialize the motion states of the spindle, radial feed axis, and extrusion wheel axis. Drive the spindle to rotate the outer gear sleeve at a speed adapted to the spindle speed, and simultaneously drive the extrusion wheel axis to rotate the extrusion wheel synchronously with the spindle according to the meshing transmission ratio. During the synchronization process, the speed deviation is corrected in real time through the electronic gearbox. Drive the radial feed axis to drive the extrusion wheel to feed radially towards the workpiece gradually according to the segmented feed strategy and the adapted feed speed, so that the extrusion wheel applies an adapted extrusion force to the outer spline of the outer gear sleeve. After the extrusion wheel feed displacement reaches the specified tooth width and the extrusion force stabilizes for a specified time, control each axis to stop moving, and complete the extrusion forming of the inverted conical teeth of the outer gear sleeve.
[0023] The real-time monitoring and control module is triggered to collect extrusion pressure, feed displacement, and rotation angle data in real time during the operation of the CNC extrusion feed module, and compare them with the thresholds corresponding to the adapted process parameters. If the data exceeds the threshold, overload protection is immediately executed. After processing, the logic corresponding to the roundness error prediction formula is used to determine whether the workpiece is qualified, marking the unqualified outer gear sleeve and triggering the rejection mechanism. At the same time, the processing data of this batch of outer gear sleeves is recorded. The roundness error prediction calculation formula is as follows: ,in, To predict roundness error; The roundness error is based on the material reference. This refers to the real-time extrusion pressure deviation. To adapt to the extrusion pressure; This refers to the real-time feed rate deviation. To adapt to the feed rate; , To influence the weights.
[0024] The extruder life management module is run to calibrate the tooth profile accuracy of the extruder before processing. During processing, the cumulative wear of the extruder is calculated using the logic corresponding to the extruder wear calculation formula, based on the adapted process parameters from the parameter pre-adaptation module and the number of external tooth sleeves already processed on the extruder. The extruder wear calculation formula is as follows: ,in, This represents the cumulative wear and tear. The wear coefficient is the unit wear factor. The number of workpieces processed; To adapt to the extrusion pressure; The standard for extrusion wheel tooth profile accuracy calibration is: the tooth pitch deviation and the radial runout of the tooth ring both meet the requirements for the forming accuracy of the inverted conical teeth. When the cumulative wear reaches the specified threshold, the system prompts the extrusion wheel to be refurbished or replaced. After the extrusion wheel is refurbished, the tooth profile accuracy is recalibrated, and it can only be put into the next batch of processing after passing the calibration.
[0025] In summary, this embodiment addresses the machining scenario of automotive synchronizer outer gear sleeves by achieving high-precision machining through the collaborative operation of various modules: the parameter pre-adaptation module calls the corresponding material reference parameters and generates adapted process parameters by combining the dynamic adaptation formula logic of extrusion pressure; the flexible clamping module adjusts the clamping force according to the adapted extrusion pressure and simultaneously detects the clamping accuracy to solve the deformation problem of thin-walled parts; the CNC extrusion feed module completes the tooth forming by using a segmented feed strategy and synchronous rotation control; the real-time monitoring and control module uses the roundness error prediction formula logic to screen qualified parts; and the extrusion roller life management module manages the extrusion roller status through the extrusion roller wear calculation formula logic. The entire process covers parameter adaptation, clamping, forming, monitoring, and maintenance to ensure the machining accuracy of thin-walled inverted conical teeth and meet the quality requirements of automotive synchronizer components.
[0026] Example 2: Machining of Inverted Tapered Gear Sleeves for Engineering Machinery Gearboxes The specific process is as follows: Figure 2 As shown: The parameter pre-adaptation module is activated. Since the workpiece to be processed is an inverted conical gear sleeve for a gearbox in engineering machinery, the mechanical parameters, reference process parameters, and parameter correction coefficients of 40Cr material are first imported through the system functions. A specified number of 40Cr material workpieces are selected for processing tests to check the tooth profile accuracy and roundness of the test workpieces. After the pass rate meets the specified requirements, the reference process parameters of 40Cr material are entered into the reference process parameter library. Subsequently, the reference parameters are retrieved, the workpiece hardness and the deviation from the ambient temperature are checked, and the logical correction parameters corresponding to the extrusion pressure dynamic adaptation formula are used to obtain the adapted process parameters.
[0027] The flexible clamping module is activated, and the arc-shaped grippers of the flexible ring-shaped fixture are adjusted to fit the outer circle of the inverted conical tooth sleeve. The clamping force is adjusted according to the clamping force-extrusion force correlation logic based on the appropriate extrusion force. Due to the deviation of the processing environment temperature from the room temperature reference, the thickness of the low expansion coefficient alloy temperature compensation shim built into the fixture base is adjusted to compensate for the deformation of the fixture base. The tooth sleeve is axially positioned by the locating pin. After the coaxiality and initial roundness are checked and found to be qualified, a ready signal is sent.
[0028] The CNC extrusion feed module is activated to initialize the motion state of each axis. The spindle with gear sleeve and the extrusion wheel shaft with extrusion wheel are driven to rotate synchronously according to the meshing transmission ratio, and the speed deviation is corrected by the electronic gearbox. The radial feed shaft with extrusion wheel is driven to feed gradually according to the segmented feed strategy and the appropriate feed speed, and the appropriate extrusion force is applied. The independent servo drive unit equipped with the extrusion wheel shaft monitors the rotational torque in real time. If the torque exceeds the specified multiple of the rated torque, the speed of the extrusion wheel shaft is immediately reduced, and the original speed is restored after the torque drops. After the extrusion wheel displacement reaches the specified tooth width and the pressure stabilizes for the specified time, the motion of each axis is stopped.
[0029] The real-time monitoring and control module is triggered to collect processing data in real time and compare it with the threshold of the adaptive parameters. If the threshold is exceeded, overload protection is executed. Overload protection is executed in two levels: when the real-time extrusion pressure reaches the first specified ratio of the adaptive extrusion pressure, the feed speed is reduced; when it exceeds the second specified ratio, the feed is paused and the position is maintained. If it does not fall back, it is stopped immediately. After processing, the passability is judged by the logic corresponding to the roundness error prediction formula, unqualified parts are marked and removed, and the processing data is recorded.
[0030] The extrusion wheel life management module is run. Before processing, a combination of a coordinate measuring machine and a laser profilometer is used to detect the tooth pitch deviation, radial runout of the tooth ring, and tooth profile error of the extrusion wheel, and to calibrate the tooth profile accuracy. During processing, the cumulative wear amount is calculated using the logic corresponding to the extrusion wheel wear amount calculation formula, based on the appropriate process parameters and the number of workpieces being processed. When the specified threshold is reached, the extrusion wheel is prompted to be repaired or replaced. After repairing and recalibrating, the extrusion wheel is put into processing after passing the test.
[0031] In summary, this embodiment addresses the machining scenario of inverted conical gear sleeves for engineering machinery gearboxes, enhancing material adaptability and operational condition handling capabilities throughout the entire process: the parameter pre-adaptation module first updates the 40Cr material benchmark parameter library, then generates adaptive parameters based on the dynamic adaptation formula logic of extrusion pressure; the flexible clamping module compensates for the influence of ambient temperature through temperature compensation pads, ensuring clamping stability; the CNC extrusion feed module manages torque using an independent servo drive unit to avoid overload damage; the real-time monitoring and control module enhances machining safety with two-stage overload protection; and the extrusion wheel life management module uses combined detection to calibrate the extrusion wheel accuracy, adapting to the machining needs of engineering machinery parts throughout the entire process, balancing material scalability and machining stability, and improving the applicability and reliability of machining inverted conical gears made of high-hardness materials.
[0032] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.
Claims
1. A CNC meshing cold extrusion reverse bevel gear intelligent feed control system, characterized in that, The system includes: Parameter pre-adaptation module: Based on the material of the workpiece to be processed, the module retrieves the reference process parameters from the parameter library, detects the surface hardness of the workpiece and the temperature of the processing environment to obtain deviation data, combines the deviation data and uses the logic corresponding to the dynamic adaptation formula of the extrusion force to correct the reference process parameters, and obtains the adapted process parameters including the adapted extrusion force, the adapted feed speed and the adapted spindle speed. Flexible clamping module: Adjust the arc-shaped jaws of the flexible ring clamp to fit the outer circle of the workpiece, adjust the clamping force of the jaws on the workpiece according to the parameter pre-adaptation module's adaptation extrusion force according to the clamping force-extrusion force correlation logic, and perform axial positioning of the workpiece through the positioning pins of the clamp base, and detect the coaxiality and initial roundness of the workpiece after clamping. CNC extrusion feed module: Initialize the spindle, radial feed axis, and extrusion wheel axis; drive the spindle and extrusion wheel axis to rotate synchronously according to the meshing transmission ratio; drive the radial feed axis to drive the extrusion wheel to feed gradually according to the segmented feed strategy and the appropriate feed speed and apply appropriate extrusion force; after the extrusion wheel feed displacement reaches the specified tooth width and the extrusion force stabilizes for the specified time, stop the movement of each axis and complete the inverted conical tooth extrusion forming. Real-time monitoring and control module: Real-time acquisition of extrusion pressure, feed displacement, and rotation angle data are compared with the adaptive parameter thresholds. When the threshold is exceeded, overload protection is executed. The logic corresponding to the roundness error prediction formula is used to mark unqualified workpieces and trigger rejection. Processing data is recorded. Extrusion Roller Life Management Module: The extrusion roller is calibrated for tooth profile accuracy. Based on the appropriate process parameters and the number of workpieces processed, the cumulative wear of the extrusion roller is calculated using the logic corresponding to the extrusion roller wear calculation formula. When the wear reaches the specified threshold, the module prompts for repair or replacement. After repair, the extrusion roller is recalibrated.
2. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The formula for calculating the dynamic adaptation of extrusion pressure in the parameter pre-adaptation module is as follows: ,in, To adapt to the extrusion pressure; The extrusion pressure is based on the material. This refers to the material property coefficient; This refers to the workpiece hardness deviation. This represents the material hardness threshold. Temperature coefficient; This refers to temperature deviation.
3. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The formula for calculating the relationship between clamping force and compressive force in the flexible clamping module is as follows: ,in, To adjust the clamping force; Clamping force is based on wall thickness; To accommodate the difference between the extrusion pressure and the reference extrusion pressure; The reference extrusion pressure; This refers to the deviation in workpiece wall thickness. This is the baseline value for wall thickness.
4. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The segmented feeding strategy in the CNC extrusion feed module is as follows: In the initial feeding stage, the goal is to quickly approach the workpiece, and the radial feed axis is controlled to drive the extrusion roller at a rate higher than the appropriate feed speed; in the middle feeding stage, the goal is to ensure stable tooth profile formation, and the radial feed axis is controlled to drive the extrusion roller at a rate appropriate to the feed speed; in the final feeding stage, the goal is to optimize the tooth profile finishing accuracy, and the radial feed axis is controlled to drive the extrusion roller at a rate lower than the appropriate feed speed; when the spindle and the extrusion roller shaft rotate synchronously, the speed deviation is corrected in real time through the electronic gearbox to ensure that the synchronization accuracy of the rotation angle of the two meets the requirements for the formation of the inverted conical teeth.
5. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The flexible clamping module has a built-in temperature compensation shim in the fixture base; the temperature compensation shim is made of a low expansion coefficient alloy, and the thermal expansion coefficient of the alloy meets the deformation compensation requirements of the fixture base; when the processing environment temperature deviates from the room temperature reference, the thickness of the temperature compensation shim is adjusted to compensate for the deformation of the fixture base caused by the temperature change.
6. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The extrusion roller shaft of the CNC extrusion feed module is equipped with an independent servo drive unit; the servo drive unit monitors the rotational torque of the extrusion roller shaft in real time, and when the rotational torque exceeds a specified multiple of the rated torque of the extrusion roller shaft, it reduces the speed of the extrusion roller shaft to a specified ratio of the reference speed; Once the rotational torque drops to within a specified multiple of the rated torque, the extruder shaft is controlled to return to its original speed.
7. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The overload protection of the real-time monitoring and control module is implemented in two levels: Level 1 overload occurs when the real-time extrusion pressure reaches a first specified ratio of the appropriate extrusion pressure, and the radial feed axis is controlled to reduce the feed speed; Level 2 overload occurs when the real-time extrusion pressure exceeds a second specified ratio of the appropriate extrusion pressure, and the radial feed axis is controlled to pause feeding and maintain the current position. If the extrusion pressure does not drop, an emergency stop is triggered; wherein, the second specified ratio is greater than the first specified ratio.
8. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The formula for predicting roundness error in the real-time monitoring and control module is as follows: ,in, To predict roundness error; The roundness error is based on the material reference. This refers to the real-time extrusion pressure deviation. To adapt to the extrusion pressure; This refers to the real-time feed rate deviation. To adapt to the feed rate; , To influence the weights.
9. The intelligent feed control system for CNC meshing cold extrusion reverse bevel gears according to claim 1, characterized in that, The formula for calculating extruder wear in the extruder life management module is as follows: ,in, This represents the cumulative wear and tear. The wear coefficient is the unit wear factor. The number of workpieces processed; To adapt to the extrusion pressure; The reference extrusion pressure is used; the calibration standard for the extrusion wheel tooth profile accuracy is: the tooth pitch deviation and the radial runout of the tooth ring both meet the requirements for the forming accuracy of the inverted conical teeth.