Micro-module internal meshing bevel gear machining device and machining method thereof

Abstract

This invention relates to the field of bevel gear machining technology, and particularly to a machining equipment and method for micro-module internal meshing bevel gears, comprising a gear shaper and a worktable; a shaping tool is connected to the gear shaper; a motion mechanism is provided on the worktable; a slide is connected to the motion mechanism; a rotating sleeve is fixed on the gear shaper; a rotating shaft rotatably connected to the rotating sleeve is fixed on the slide; and a locking mechanism is provided on the gear shaper for locking onto the slide. When using this invention, the angle between the tool axis and the workpiece axis during gear shaping is adjustable, significantly improving the machining adaptability and tooth direction accuracy of complex tooth profiles; moreover, it can machine parallel gears, non-involute gears, and bevel gears, enriching the types of gears that can be machined.

Description

Technical Field

[0001] This invention relates to the field of bevel gear processing technology, and in particular to a processing equipment and method for micro-module internal meshing bevel gears. Background Technology

[0002] In medical dental surgery, micro-module bevel gear transmissions (module less than 0.5mm) are used. The products are required to have a speed of more than 200,000 revolutions per minute and have high noise, vibration, temperature rise and life indicators. This requires bevel gears to have high meshing performance, and the correctness of the tooth profile is crucial.

[0003] The gear shaper cutter of the existing vertical gear shaper performs a reciprocating cutting motion under the drive of the spindle. The cutting motion of the vertical gear shaper is easily affected by gravity. Because micro-module bevel gears are small in size and require high precision, the vertical gear shaper cannot process the existing micro-module bevel gears.

[0004] Existing vertical gear shaping technology cannot be used to process micro-module internal meshing bevel gears using the generating method. Gear shaping machines are also not compatible with machining principles. Conventional manufacturing processes use dedicated bevel gear planers or bevel gear milling machines, but the cutting tools on these machines extend into the gear's internal cavity. Given the micro-sized product, the cutting tools cannot reach this depth, making it impossible to produce small-module gears. If contour machining is used, the gears produced by contour machining cannot achieve conjugate meshing, resulting in noise, vibration, and temperature rise issues during high-speed operation, failing to meet quality standards. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings and deficiencies of existing technologies by providing a machining equipment for micro-module internal meshing bevel gears.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: The present invention discloses a micro-module internal meshing bevel gear processing equipment, comprising a gear shaper and a worktable; the gear shaper is equipped with a shaping tool. The worktable consists of a rear feeding mechanism and an electric spindle; the rear feeding mechanism, the electric spindle, and the gear shaper are arranged sequentially along the horizontal direction of the electric spindle; a motion mechanism is provided on the worktable; a slide is connected to the motion mechanism; A rotating shaft sleeve is fixed on the gear hobbing machine; a rotating shaft that is rotatably connected to the rotating shaft sleeve is fixed on the slide table; and a locking mechanism for locking the gear hobbing machine onto the slide table is provided on the gear hobbing machine.

[0007] Furthermore, the motion mechanism includes an X-line module and a Y-line module; one end of the X-line module is fixed to the worktable; the other end of the X-line module is fixed to one end of the Y-line module; and the other end of the Y-line module is fixed to the slide.

[0008] Furthermore, a base is provided on the slide; a cutting blade, a surface machining blade, and an internal hole machining blade are provided on the base.

[0009] Furthermore, the insert has a cylindrical structure; multiple machining teeth are evenly distributed on the inner sidewall of the insert.

[0010] Furthermore, in the insert disc structure, multiple machining teeth are evenly distributed around the outer circumference of the disc's outer side wall.

[0011] Furthermore, the swing angle of the gear hobbing machine is -45 degrees to 45 degrees.

[0012] A processing method for a bevel gear processing equipment, characterized by comprising the following steps: ① Adjust the angle of the plug according to the pitch cone angle of the gear to be processed, so as to ensure that the angle between the reciprocating motion direction of the cutter and the axis of the workpiece is equal to the pitch cone angle of the workpiece; ② Set the speed ratio between the cutter and the workpiece according to the number of cutting teeth on the cutter and the number of teeth on the workpiece; set the feed of the cutter towards the workpiece axis per revolution according to the tooth height; ③ Set the reciprocating distance of the tool according to the effective length of the tooth surface of the workpiece to be machined; ④ Set the reciprocating speed of the inserting tool; ⑤ Begin processing.

[0013] Furthermore, the following conditions must be met in the aforementioned steps: Where d is the cutting tool, p is the workpiece, N is the rotational speed, and Z is the number of teeth.

[0014] With the above structure, the beneficial effects of the present invention are as follows: 1. This equipment completes the blank turning and gear shaping in one operation. The gear shaping head is designed with a horizontal structure to eliminate the need for a separate blank turning process, thereby improving production efficiency. It also avoids errors caused by secondary clamping of the blank, improving product quality. Furthermore, it eliminates the need for blank fixtures, saving on expensive fixture manufacturing costs. 2. This equipment can adjust the swing angle of the gear shaper to adjust the angle between the cutting tool's movement trajectory and the workpiece axis, and can produce modified bevel gears at any angle; it realizes the adjustable angle between the tool axis and the workpiece axis during the gear shaping process, which significantly improves the processing adaptability and tooth direction accuracy of complex tooth profiles; moreover, it can process parallel gears, non-involute gears and bevel gears, enriching the types of gears that can be processed.

[0015] 3. The micro-module internal meshing bevel gear machining solution in this method modifies this type of gear. The tooth profile of the internal gear is designed as a parallel straight profile (i.e., a plane, not an involute), and this tooth profile is used as the generating wheel of the pinion to make a shaping tool. The pinion is machined using the generating method, which can achieve conjugate tooth profiles of the two gears. Thus, since the tooth profile of the internal gear is a parallel straight profile (plane), conventional milling processes can be used to cut the teeth, which is relatively simple and the quality is easy to guarantee. For the machining of the small bevel gear (external gear), the tooth profile of the internal gear can be used as the shaping tool profile for shaping, which can obtain the conjugate tooth profiles of the two gears and solve the problems of noise, vibration, and temperature rise when the gears are running at high speed. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a structural diagram of the present invention with the outer casing of the lathe body removed; Figure 3 It is a structural diagram of the motion mechanism integrating the slide, gear shaper, and cutting tool; Figure 4 This is a structural diagram showing the machining method of the cutting teeth on the inner wall of the cylinder; Figure 5 It is a structural diagram of the workpiece; Explanation of reference numerals in the attached figures: 1. Lathe body; 2. Rear feed mechanism; 3. Electric spindle; 4. Gear shaper; 401. Gear cutter; 40101, Machining cutter teeth; 402, Rotary bushing; 5, X-line module; 6, Slide table; 7. Y-linear module; 8. Base; 9. Cutting blade; 10. Surface finishing blade; 11. Internal machining tool; 12. Workpiece. Detailed Implementation

[0017] The invention will now be further described with reference to the accompanying drawings.

[0018] like Figures 1 to 5 As shown, the present invention provides a micro-module internal meshing bevel gear processing equipment, including a gear shaper 4 and a worktable; the gear shaper 4 is connected to a cutter 401.

[0019] The gear shaper 4 is not fundamentally different from existing technology, so it will not be described in detail. The cutting tool 401 is detachably connected to the tool holder of the gear shaper 4. The gear shaper 4 is internally equipped with a rotating mechanism and a reciprocating telescopic mechanism. The rotating mechanism is used to drive the tool holder to rotate. Since the reciprocating telescopic mechanism and the tool holder are connected by a rotation, the rotating mechanism will not drive the reciprocating telescopic mechanism to rotate when it moves. The rotating mechanism and the tool holder are connected by a sliding connection, so the reciprocating telescopic mechanism will not cause the rotating mechanism to rotate when it drives the tool holder to move.

[0020] A motion mechanism is provided on the workbench; a slide table 6 is connected to the motion mechanism.

[0021] A rotating shaft sleeve 402 is fixed on the gear hobbing machine 4; a rotating shaft that is rotatably connected to the rotating shaft sleeve 402 is fixed on the slide table 6; and a locking mechanism for locking the gear hobbing machine 4 onto the slide table 6 is provided.

[0022] The slide table 6 has an arc-shaped guide rail coaxial with the rotating shaft on its surface; a roller structure that slides along the arc-shaped guide rail is provided at the bottom of the gear shaper 4; when the roller structure slides along the arc-shaped guide rail, it drives the gear shaper to make a precise arc swing around the center of the rotating shaft, which can adjust the swing angle of the gear shaper 4 and realize the angle adjustment between the movement trajectory of the cutter 401 and the axis of the workpiece 12, and can process bevel gears with various bevel angles. After the angle of the gear shaper 4 is adjusted, the locking mechanism can rigidly fix the gear shaper on the slide table to ensure stable processing posture. The locking mechanism can be a bolt, with multiple threaded holes set at corresponding positions on the slide table 6, arranged in a circumferential pattern. After the bolt is locked in different threaded holes for positioning, the gear shaper 4 can be positioned at different angles. This structure realizes the adjustable angle between the tool axis and the workpiece axis during the gear shaping process, significantly improving the processing adaptability and tooth direction accuracy of complex tooth profiles. Moreover, it can process external bevel gears that mate with parallel straight internal teeth, internal bevel gears that mate with cylindrical external spur gears, end face gears, and high-ratio external bevel gears that mate with cylindrical external spur gears, enriching the types of gears that can be processed.

[0023] In a preferred embodiment of the present invention, the motion mechanism includes an X-line module 5 and a Y-line module 7; one end of the X-line module 5 is fixed to the worktable; the other end of the X-line module 5 is fixed to one end of the Y-line module 7; and the other end of the Y-line module 7 is fixed to the slide table 6. Both the X-line module 5 and the Y-line module 7 are not fundamentally different from existing technologies, so they will not be discussed in detail. X-linear module 5 is used to drive Y-linear module 7 to move along the X direction on the worktable. Y-linear module 7 is used to drive slide 6 to move relative to Y-linear module 7 along the Y direction. This enables the processing of gears of different diameters and improves the applicability of the processing.

[0024] In a preferred embodiment of the present invention, a base 8 is provided on the slide table 6; a cutting blade 9, a surface machining blade 10, and an internal hole machining blade 11 are provided on the base 8; the worktable is composed of a rear feeding mechanism 2 and an electric spindle 3; the rear feeding mechanism 2, the electric spindle 3, and the gear shaper 4 are arranged sequentially along the horizontal direction of the electric spindle 3; the rear feeding mechanism 2, the electric spindle 3, and the gear shaper 4 arranged in the horizontal direction form a horizontal structure, reducing the impact force of cutting.

[0025] The electric spindle 3 and the gear shaper 4 are located inside the lathe body 1, while the rear feeding mechanism 2 is located outside the lathe body 1. To better understand the processing technology of the integrated machine of the present invention, the rear feeding mechanism 2 and the electric spindle 3 are briefly described below: The rear feeding mechanism 2 is provided with a storage rack for placing round bars and a feeding part for conveying the round bars forward. The rear feeding mechanism 2 is also provided with a lifting part for conveying the round bars to the storage rack and then to the feeding part. The electric spindle 3 is provided with a chuck, and the electric spindle 3 is provided with a through hole. The electric spindle 3 can drive the chuck to rotate.

[0026] The working principle of the linkage between the rear feeding mechanism 2 and the electric spindle 3 is as follows: the round bar enters the feeding section from the storage rack through the lifting part, the feeding part of the rear feeding mechanism 2 feeds the round bar to the through hole of the electric spindle 3, and fixes it through the chuck. The electric spindle 3 drives the round bar to make a rotary motion. That is, the linkage between the rear feeding mechanism 2 and the electric spindle 3 plays the roles of feeding, clamping, and rotating, realizing the automatic loading of workpieces.

[0027] The machine tool composed of the rear feeding mechanism 2 and the electric spindle 3 is widely used in the processing of long bar materials; the rear feeding mechanism 2 and the electric spindle 3 are not fundamentally different from the existing technology, so they will not be discussed in detail here.

[0028] The cutting tool 9, the surface finishing tool 10 (e.g., an external turning tool), and the internal hole finishing tool 11 (e.g., a boring tool or a drill bit) are not fundamentally different from existing tool structures, so they will not be discussed in detail.

[0029] The motion mechanism drives the surface machining cutter 10 on the slide table 6 to move, and the round bar is driven to rotate by the electric spindle 3. The surface machining cutter 10 can process the round bar into a cylindrical structure or a conical structure. Then, the cutting cutter 9 cuts and separates the processed product from the round bar, thus obtaining the workpiece 12. Next, the feeding mechanism 2 continues to push the remaining material inside the electric spindle 3 forward to a set distance, and then continues to process the next workpiece 12. The internal hole machining cutter 11 can be used to process the internal hole of the workpiece. The internal hole machining process is not fundamentally different from the existing technology, so it will not be described in detail here.

[0030] This equipment, with its integrated turning and shaping structure, eliminates the need for multiple positioning of the round bar or gear blank, avoiding the difficulties of clamping small gears on the gear shaper and the error of secondary clamping, while improving work efficiency.

[0031] This equipment uses an integrated machining structure for both turning and inserting, which allows multiple machining processes to be clamped and positioned at once on the electric spindle 3, thus improving machining accuracy.

[0032] As a preferred embodiment of the present invention, such as Figure 4As shown, the insert 401 has a cylindrical structure; multiple machining teeth 40101 are evenly distributed on the inner sidewall of the insert 401; the insert 401 is set as an internal gear, the tooth profile of the internal gear is designed as a parallel straight profile (i.e., a plane, not an involute), and this tooth profile is used as a forming wheel to make the insert. Then, the generating method is used to process the small gear workpiece, which can realize the conjugate tooth profile of the two gears. When processing the small bevel gear, the tooth profile of the internal gear is used as the tooth profile of the insert, and the gear shaping is performed to obtain the conjugate tooth profile of the two gears, which can process gears with small modules.

[0033] As a preferred embodiment of the present invention, the inserter 401 has a disc structure, and a plurality of machining teeth 40101 are evenly distributed on the outer side wall of the disc.

[0034] As a preferred embodiment of the present invention, the swing angle of the gear shaper 4 is -45 degrees to 45 degrees, which facilitates the use of the gear shaper cutter for machining non-involute micro-module bevel gears.

[0035] A processing method for a bevel gear processing equipment includes the following steps: ① Adjust the angle of the plug according to the cone angle of the gear to be processed, so as to ensure that the direction of the tool movement is consistent with the cone angle of the gear; during adjustment, loosen the bolt on the locking mechanism, so that the gear shaper 4 rotates around the shaft to the specified angle, and then tighten the bolt again to fix it on the slide table 6. ② Set the speed ratio between the cutter 401 and the workpiece 12 according to the number of cutting teeth 40101 on the cutter 401 and the number of teeth on the workpiece 12; set the feed of the cutter 401 towards the axis of the workpiece 12 per revolution according to the tooth height; the speed of the workpiece 12 is controlled by the electric spindle 3; the speed of the cutter 401 is controlled by the gear shaper 4. Taking a tooth with 7 teeth and a tooth height of 1mm as an example, the Y linear module 7 drives the gear shaper 4 to move along the axis of the workpiece 12, thereby controlling the cutter 401 to feed at a constant speed towards the axis of the workpiece 12. When the workpiece 12 is set to rotate two revolutions to complete the processing of a tooth height of 1mm, after the workpiece 12 rotates one revolution, the cutter 401 feeds 0.5mm towards the workpiece 12. ③ Set the reciprocating distance of the cutter 401 according to the effective length of the tooth surface of the workpiece 12 to be processed; the extension length of the cutter 401 driven by the gear shaper 4 is determined by the stroke of the reciprocating telescopic mechanism of the gear shaper 4, so the reciprocating distance of the cutter 401 can be adjusted by adjusting the eccentric part inside the reciprocating telescopic mechanism; all existing gear shapers 4 have a structure for adjusting the extension stroke. ④ Set the reciprocating speed of the cutting tool 401. The reciprocating telescopic mechanism of the gear shaping machine 4 controls the speed of the cutting tool 401, which is determined by the speed of the motor. ⑤ Begin processing.

[0036] In a preferred embodiment of the present invention, step 2 needs to satisfy the following: Where d is the cutting tool 401, p is the workpiece 12, N is the rotational speed, and Z is the number of teeth. That is, the ratio of the rotational speed of the cutting tool 401 to the rotational speed of the workpiece 12 is equal to the ratio of the number of teeth of the workpiece 12 to the number of machining teeth 40101 of the cutting tool 401; the tool and the workpiece automatically form a linkage motion trajectory according to this formula.

[0037] It should be noted that when the gear shaper 4 is working, the rotation of the cutter 401 and its reciprocating cutting motion are independent of each other; that is, the cutter 401 does not perform reciprocating cutting motion when rotating, and it does not rotate when reciprocating cutting motion. The rotation speed and reciprocating cutting motion speed of the cutter 401 are set according to the structure of the gear shaper 4. The angle of rotation of the cutter 401 in two adjacent reciprocating cutting motions is the single rotation angle. The single rotation angle is set on the gear shaper 4. The smaller the single rotation angle, the smoother the surface of the gear it processes; conversely, the larger the single rotation angle, the rougher the surface of the gear it processes. For example, the number of teeth on the cutter 401 is already determined, the number of teeth on the workpiece 12 is also determined, and the speed ratio is determined; Based on the speed ratio obtained above, the speed of the electric spindle 3 and the speed of the tool cutter 401 are set on the control panel of the lathe body 1. When workpiece 12 is fixed by electric spindle 3, gear shaper 4 moves to the pre-machining position according to the program and then performs gear shaping, as follows: First, the inserter 401 rotates by a single rotation angle, and at the same time, the workpiece 12 rotates by the corresponding angle according to the above-mentioned speed ratio and then stops rotating; In the second step, the cutting tooth 40101 on the gear shaper 4 makes one reciprocating motion, and the cutting tooth 40101 cuts the workpiece 12 once, producing a cutting plane; Third step: After the plane is machined, the cutting tooth 40101 on the gear shaper 4 is completed and withdrawn; Fourth step, then continue repeating the first to third steps above to complete the second cutting plane, until the workpiece 12 has rotated to the set number of revolutions; This process of cutting each tooth multiple times creates multiple cutting planes until the desired shape is achieved, at which point the cutting stops, thus completing the machining of the entire tooth. The principle of cutting each tooth multiple times is the same as that of existing generating methods, so the process of cutting multiple cutting planes in each tooth will not be explained in detail here.

[0038] The above description is only a preferred embodiment of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of this patent application are included in the scope of this patent application.

Claims

1. A micro-module internal meshing bevel gear processing equipment, comprising a gear shaper (4) and a worktable; the gear shaper (4) is connected to a gear cutter (401). Its features are: The worktable is composed of a rear feeding mechanism (2) and an electric spindle (3); the rear feeding mechanism (2), the electric spindle (3) and the gear shaper (4) are arranged in sequence along the horizontal direction of the electric spindle (3); a motion mechanism is provided on the worktable; a slide table (6) is connected to the motion mechanism. A rotating shaft sleeve (402) is fixed on the gear hobbing machine (4); a rotating shaft that is rotatably connected to the rotating shaft sleeve (402) is fixed on the slide table (6); and a locking mechanism for locking onto the slide table (6) is provided on the gear hobbing machine (4).

2. The micro-module internal meshing bevel gear processing equipment according to claim 1, characterized in that: The motion mechanism includes an X-line module (5) and a Y-line module (7); one end of the X-line module (5) is fixed on the worktable; the other end of the X-line module (5) is fixed on one end of the Y-line module (7); the other end of the Y-line module (7) is fixed on the slide table (6).

3. The micro-module internal meshing bevel gear processing equipment according to claim 2, characterized in that: A base (8) is provided on the slide (6); a cutting blade (9), a surface machining blade (10) and an internal hole machining blade (11) are provided on the base (8).

4. The micro-module internal meshing bevel gear processing equipment according to claim 2, characterized in that: The inserter (401) has a cylindrical structure; the inner sidewall of the inserter (401) is evenly distributed with multiple machining teeth (40101).

5. The micro-module internal meshing bevel gear processing equipment according to claim 1, characterized in that: The inserter (401) has a disc structure, and multiple machining teeth (40101) are evenly distributed on the outer side wall of the disc.

6. The micro-module internal meshing bevel gear processing equipment according to claim 1, characterized in that: The swing angle of the gear hobbing machine (4) is -45 degrees to 45 degrees.

7. The processing method of the bevel gear processing equipment according to any one of claims 1-6, characterized in that: Includes the following steps: ① Adjust the angle of the plug according to the pitch cone angle of the gear to be processed, so as to ensure that the angle between the reciprocating motion direction of the cutter (401) and the axis of the workpiece (12) is equal to the pitch cone angle of the workpiece (12); ② Set the speed ratio between the cutter (401) and the workpiece (12) according to the number of cutting teeth (40101) on the cutter (401) and the number of teeth on the workpiece (12). Set the feed of the cutter (401) towards the axis of the workpiece (12) in each revolution according to the tooth height. ③ Set the reciprocating distance of the cutter (401) according to the effective length of the tooth surface of the workpiece (12) to be processed; ④ Set the reciprocating speed of the insert (401); ⑤ Begin processing.

8. The processing method of the bevel gear processing equipment according to claim 7, characterized in that: Step 2 requires the following to be satisfied: , where d is the cutting tool (401), p is the workpiece (12), N is the rotational speed, and Z is the number of teeth.

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