Compound machine tool and machining method integrating five-axis linkage turning-milling and horizontal gear hobbing functions

Abstract

The present application relates to the technical field of numerical control machine tools, and discloses a compound machine tool integrating five-axis linkage turning-milling and horizontal gear hobbing functions and a machining method, comprising a base, a saddle, an X-axis sliding plate, an A2 rotary table, a rotatable column, a hobbing spindle unit, a swing turning-milling spindle unit, a turning spindle unit, an auxiliary tailstock spindle unit and a multi-motion axis system. The rotatable column is rotated by 180 degrees through the A2 rotary table to switch the machining mode, and double vertical guide mechanisms enable two sets of spindle units to move independently without interference; the turning spindle and the auxiliary tailstock spindle coaxially support the workpiece to complete the whole-process machining in one clamping. The present application integrates the functions of turning-milling and horizontal gear hobbing, is quick in mode switching, high in machining precision and strong in overall rigidity, effectively solves the problems of dispersed traditional machining processes, large clamping errors, high equipment investment and low production efficiency, and is suitable for integrated machining of high-precision gears and complex shaft parts.

Description

Technical Field

[0001] This invention relates to the field of CNC machine tool technology, specifically to a composite machine tool and machining method that integrates five-axis linkage turning and milling with horizontal gear hobbing functions. Background Technology

[0002] Gears and complex shafts are core components of mechanical equipment, and their machining accuracy and production efficiency directly determine the overall performance and manufacturing cycle of the equipment. Currently, the machining technology for these parts in the industry has significant shortcomings, with the core pain points as follows:

[0003] 1. Dispersed processes and multiple clamping lead to loss of precision control: Turning needs to be completed on a CNC lathe, milling depends on a machining center, and gear hobbing requires a special gear hobbing machine. The step-by-step processing of multiple machines requires the workpiece to be clamped and positioned multiple times. The cumulative clamping errors lead to a significant reduction in the machining accuracy of the parts, poor dimensional consistency, and difficulty in meeting the machining requirements of high-precision gears.

[0004] 2. High equipment investment and low production efficiency: Traditional milling and turning machines only integrate turning and milling functions and have no gear hobbing capability; dedicated gear hobbing machines have limited functions and cannot complete pre-processing steps such as turning and milling. Enterprises need to purchase multiple dedicated machines, resulting in high costs for equipment purchase, maintenance, and production space occupation. In addition, the time-consuming workpiece transfer between processes and the high labor costs lead to low overall production efficiency.

[0005] 3. Existing composite equipment has technical shortcomings: The few composite machine tools that attempt to integrate multiple processing functions generally suffer from problems such as unreasonable structural layout, insufficient linkage capability of motion axes, and limited processing range. Some equipment cannot achieve high-precision linkage between gear hobbing and milling and turning, some equipment has cumbersome processing mode switching, poor adaptability to gears with different modules and helix angles, and it is difficult to meet the high-precision and high-efficiency integrated processing needs of complex parts.

[0006] In summary, the existing technology lacks a composite machine tool with a reasonable structural design, high multi-axis linkage precision, and convenient machining mode switching. It cannot fundamentally solve the problems of low precision, low efficiency, and high cost in the machining of gears and complex shaft parts. There is an urgent need to develop a multi-functional composite machine tool that integrates turning and milling and horizontal gear hobbing functions. Summary of the Invention

[0007] The purpose of this invention is to provide a composite machine tool and machining method that integrates five-axis linkage turning and milling with horizontal gear hobbing functions, so as to solve the above-mentioned defects.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] The present invention proposes a composite machine tool integrating five-axis linkage milling and turning with horizontal gear hobbing functions, comprising a base, a saddle, an X-axis slide plate, an A2 rotary table, a rotatable column, a gear hobbing spindle unit, a swing milling and turning spindle unit, a turning spindle unit, an auxiliary tailstock spindle unit, a workpiece, and a multi-axis motion system; the saddle and the base slide in a horizontal left-right direction, and the X-axis slide plate slides in a horizontal front-back direction; the A2 rotary table connects the X-axis slide plate and the rotatable column, and is used to drive the rotatable column to rotate to achieve machining mode switching; the rotatable column is provided with independent first vertical... The system includes a straight guide mechanism and a second vertical guide mechanism. The gear hobbing spindle unit cooperates with the first vertical guide mechanism, and the oscillating milling and turning spindle unit cooperates with the second vertical guide mechanism. The two mechanisms move independently without interference. The turning spindle unit and the auxiliary tailstock spindle unit are arranged opposite each other on the base for clamping, driving, and supporting the workpiece. The multi-axis motion system includes X-axis, Z-axis, Y1-axis, Y2-axis, A1-axis, A2-axis, B1-axis, B2-axis, C1-axis, and C2-axis, and drives each component to work together to achieve integrated machining of horizontal milling and turning and horizontal gear hobbing.

[0010] Preferably, the Z-axis includes a Z1-axis assembly and a Z2-axis assembly; the Z1-axis assembly includes a Z1-axis guide rail, a Z1-axis lead screw, and a Z1-axis motor mounted on the base. The Z1-axis guide rail is arranged in a horizontal left-right direction. The saddle is slidably connected to the Z1-axis guide rail and threadedly engaged with the Z1-axis lead screw, and is driven by the Z1-axis motor to move in the horizontal left-right direction to achieve transverse feed; the Z2-axis assembly includes a Z2-axis guide rail, a Z2-axis lead screw, and a Z2-axis motor mounted on the base. The Z2-axis guide rail is parallel to the Z1-axis guide rail and arranged in a horizontal left-right direction. The Z2-axis motor drives the Z2-axis lead screw to rotate, which is used to assist axial feed movement and precise adjustment of machining position.

[0011] Preferably, the X-axis includes an X-axis guide rail, an X-axis lead screw, and an X-axis motor mounted on the saddle; the X-axis guide rail is arranged in a horizontal front-to-back direction, the X-axis slide plate is slidably connected to the X-axis guide rail and threadedly engaged with the X-axis lead screw, and is driven by the X-axis motor to move in the horizontal front-to-back direction to achieve longitudinal feeding.

[0012] Preferably, the Y1 axis and Y2 axis respectively include Y1 axis guide rail and Y2 axis guide rail arranged parallel to each other in the vertical direction on the side of the rotatable column. The gear hobbing spindle unit is slidably connected to the Y1 axis guide rail and is driven to lift by the Y1 axis motor and Y1 axis lead screw. The swing milling spindle unit is slidably connected to the Y2 axis guide rail and is driven to lift by the Y2 axis motor and Y2 axis lead screw. The movement of the two does not interfere with each other.

[0013] Preferably, the gear hobbing spindle unit includes upper and lower slide plates, an A1 rotary table, a B1-axis hobbing cutter spindle, and a hob. The upper and lower slide plates are slidably connected to the Y1-axis guide rail. The A1 rotary table is fixed on the upper and lower slide plates. The B1-axis hobbing cutter spindle is mounted on the A1 rotary table. The hob is fixedly connected to the B1-axis hobbing cutter spindle. The A1 rotary table is used to adjust the helix angle and installation angle of the hob. The B1-axis hobbing cutter spindle drives the hob to rotate, achieving high-precision horizontal gear hobbing. The A2 axis is an A2 rotary table, used to drive a rotatable column to rotate 180° around the horizontal axis, achieving automated switching of processing modes.

[0014] Preferably, the oscillating milling spindle unit has three interchangeable configurations, including:

[0015] (1) Power turret configuration: includes upper and lower slide plates and power turret. The power turret is installed on the upper and lower slide plates. The power turret has its own cutting power and can realize turning and milling by installing various tools.

[0016] (2) Milling and turning spindle configuration: including upper and lower slide plates, B2 axis rotary table and milling and turning power spindle. The milling and turning power spindle is mounted on the B2 axis rotary table, and the B2 axis rotary table is mounted on the upper and lower slide plates. The milling and turning power spindle has its own cutting power and can realize turning, milling and five-axis linkage machining.

[0017] (3) Electric turret configuration: including upper and lower slide plates and electric turret. The electric turret is installed on the upper and lower slide plates. The electric turret only has the power to change the tool position and no cutting power. It can only realize turning.

[0018] The upper and lower sliding plates are slidably connected to the Y2 axis guide rail; the B2 axis is a B2 axis rotary table, which exists only in the milling and turning spindle configuration and is used to adjust the tool posture to achieve five-axis linkage machining.

[0019] Preferably, the turning spindle unit includes a C1-axis spindle box and a C1-axis spindle. The C1-axis spindle box is fixedly mounted on the base. The C1-axis is the C1-axis spindle and is coaxially mounted inside the C1-axis spindle box, used to drive the workpiece to rotate and achieve indexing motion. The auxiliary tailstock spindle unit includes a C2-axis spindle (91) and a C2-axis spindle. The C2-axis spindle box is mounted on the Z2-axis guide rail of the base and slides under the control of the Z2-axis motor and Z2-axis lead screw. The C2-axis is the C2-axis spindle and is coaxially mounted inside the C2-axis spindle box, and is arranged coaxially with the C1-axis spindle, used to support and position the workpiece.

[0020] Preferably, a machining mode switching method for a composite machine tool is applied to a composite machine tool that integrates five-axis linkage milling and turning and horizontal gear hobbing functions. The rotating column is driven to rotate 180° by the A2 turntable, so that the gear hobbing spindle unit and the swing milling spindle unit switch working positions, realizing the automated and seamless switching between the horizontal milling and turning mode and the horizontal gear hobbing mode. The switching process is controlled by the CNC system, maintaining the original clamping state, and no repositioning is required.

[0021] Preferably, in the horizontal milling and turning compound mode, the turning, milling, chamfering, and deburring of the workpiece are completed according to the configuration type of the installed oscillating milling and turning spindle unit; in the horizontal gear hobbing mode, gear hobbing is completed by the indexing cooperation between the hob and the C1 axis.

[0022] Preferably, after the gear hobbing is completed, the A2 turntable drives the rotatable column to rotate 180° in the opposite direction to reset, and the machine tool switches back to the horizontal turning and milling compound mode to continue to complete the grinding and finishing of the workpiece.

[0023] The beneficial effects of this invention are as follows:

[0024] (1) One clamping for all processes, greatly improving machining accuracy: In this invention, the workpiece does not need to be disassembled and positioned again after being clamped once. It can directly complete all processes such as turning, milling, hobbing, milling, turning, chamfering, deburring, and grinding, completely avoiding positioning errors caused by multiple clamping, and significantly improving the machining accuracy and dimensional consistency of the parts.

[0025] (2) Multifunctional and highly integrated, reducing equipment investment costs: This invention integrates milling and turning machining and horizontal gear hobbing machining functions into one machine, replacing multiple machines such as CNC lathes, machining centers, and special gear hobbing machines, reducing the enterprise's equipment purchase investment, saving production site occupation, and reducing equipment maintenance and management costs.

[0026] (3) Multi-axis precise linkage, wide processing range and strong versatility: This invention achieves precise linkage through a multi-axis motion system, which can be adapted to gear processing with different modules and helix angles, and can complete the milling of complex curved surfaces and inclined surfaces, adapting to the processing needs of different industries.

[0027] (4) Rapid switching of processing modes and significantly improved production efficiency: The present invention achieves automated switching of processing modes by driving a rotatable column through an A2 turntable. The switching time is short and no manual adjustment of equipment or workpiece is required. The entire process is completed in one clamping, saving the time of workpiece transfer between processes. The overall production efficiency is greatly improved compared with the traditional processing method.

[0028] (5) High rigidity structure design to ensure processing stability and surface quality: In this invention, the base and rotatable column adopt a high rigidity structure, and each motion axis adopts a high precision guide rail. The auxiliary tailstock spindle unit realizes the support of both ends of long shaft workpieces, effectively reducing vibration and deformation during processing, ensuring the rigidity and stability of the machine tool during high-speed and heavy-load processing, and improving the surface quality of the parts.

[0029] (6) High degree of automation, reducing manual operation costs: The present invention realizes precise linkage of each axis and automated control of the machining process through the CNC system. It can compile, store and call machining programs to realize automated machining of batch parts, reduce the intensity of manual operation and manual intervention, avoid errors caused by manual operation, and reduce labor costs. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall structure of the present invention (the oscillating milling spindle unit is in a powered turret configuration mode);

[0031] Figure 2 This is a structural schematic diagram of the rotatable column, gear hobbing spindle unit, and oscillating milling and turning spindle unit (milling and turning spindle configuration mode) of the present invention;

[0032] Figure 3 This is a structural schematic diagram of the rotatable column, gear hobbing spindle unit, and oscillating milling spindle unit (electric turret configuration mode) of the present invention.

[0033] The component names corresponding to each number in the diagram are as follows:

[0034] 1. Base, 2. Saddle, 3. X-axis slide plate, 4. A2 rotary table, 5. Rotatable column, 6. Hobbing spindle unit, 7. Swing milling spindle unit, 8. Turning spindle unit, 9. Auxiliary tailstock spindle unit, 10. Workpiece, 11. Z1 axis guide rail, 12. Z1 axis lead screw, 13. Z1 axis motor, 14. Z2 axis guide rail, 15. Z2 axis lead screw, 16. Z2 axis motor, 21. X-axis guide rail, 22. X-axis lead screw, 23. X-axis motor, 51. Y1 axis guide rail, 52. Y2 axis guide rail, 61. Upper and lower slide plates one, 62. A1 rotary table, 63. B1 axis hobbing spindle, 64. Hob, 71. Upper and lower slide plates two, 72. B2 73. Turning and milling power spindle, 74. Power turret, 75. Electric turret, 81. C1 axis spindle box, 82. C1 axis spindle, 91. C2 axis spindle box, 92. C2 axis spindle. Detailed Implementation

[0035] The present invention will be further described below with reference to the embodiments. It should be noted that these are merely examples and descriptions of the inventive concept. Those skilled in the art can make various modifications or additions to the specific embodiments described or use similar methods to replace them, as long as they do not deviate from the inventive concept or exceed the scope defined in the claims, they should all be considered to fall within the protection scope of the present invention.

[0036] Example 1:

[0037] like Figure 1-3 As shown, this embodiment discloses a composite machine tool integrating five-axis linkage milling and turning and horizontal gear hobbing functions, including a base 1, a saddle 2, an X-axis slide plate 3, an A2 turntable 4, a rotatable column 5, a gear hobbing spindle unit 6, a swing milling spindle unit 7, a turning spindle unit 8, an auxiliary tailstock spindle unit 9, a workpiece 10, and a multi-axis motion system.

[0038] The saddle 2 and the base 1 slide in the horizontal left and right direction, and the X-axis slide plate 3 slides in the horizontal front and back direction; the A2 turntable 4 connects the X-axis slide plate 3 and the rotatable column 5, and is used to drive the rotatable column 5 to rotate to realize the switching of processing mode.

[0039] The rotatable column 5 is equipped with a first vertical guide mechanism and a second vertical guide mechanism that are independent of each other. The hobbing spindle unit 6 cooperates with the first vertical guide mechanism, and the oscillating milling spindle unit 7 cooperates with the second vertical guide mechanism. The two move independently without interference.

[0040] The turning spindle unit 8 and the auxiliary tailstock spindle unit 9 are arranged opposite each other on the base 1 for clamping, driving and supporting the workpiece 10.

[0041] The multi-axis motion system includes X-axis, Z-axis, Y1-axis, Y2-axis, A1-axis, A2-axis, B1-axis, B2-axis, C1-axis, and C2-axis, and drives the various components to work together to achieve integrated machining of horizontal milling and turning and horizontal gear hobbing.

[0042] Example 2:

[0043] like Figure 1-3 As shown, this embodiment discloses a composite machine tool that integrates five-axis linkage milling and turning with horizontal gear hobbing functions. Its overall structure includes a base 1, a saddle 2, an X-axis slide plate 3, an A2 turntable 4, a rotatable column 5, a gear hobbing spindle unit 6, a swing milling spindle unit 7, a turning spindle unit 8, an auxiliary tailstock spindle unit 9, a workpiece 10, and a multi-axis motion system.

[0044] The multi-axis motion system includes X-axis, Z-axis, Y1-axis, Y2-axis, A1-axis, A2-axis, B1-axis, B2-axis, C1-axis, and C2-axis, and drives the various components to work together to achieve integrated machining of horizontal milling and turning and horizontal gear hobbing.

[0045] I. The specific structure, location, and connection relationship of each component are as follows:

[0046] 1. Base.

[0047] The base 1 is the basic support component of the machine tool. It is made of HT300 high-strength cast iron and is used to support the saddle 2, the turning spindle unit 8, the auxiliary tailstock spindle unit 9 and all moving parts, ensuring the overall rigidity, vibration resistance and machining stability of the machine tool.

[0048] Z-axis related components are fixedly installed on the base 1. The Z-axis includes the Z1 axis component and the Z2 axis component.

[0049] The Z1 axis assembly includes a Z1 axis guide rail 11, a Z1 axis lead screw 12, and a Z1 axis motor 13 mounted on the base 1. The Z1 axis guide rail 11 is arranged in the horizontal left-right direction. The saddle 2 is slidably connected to the Z1 axis guide rail 11 and threadedly engaged with the Z1 axis lead screw 12. It is driven by the Z1 axis motor 13 to move in the horizontal left-right direction to achieve transverse feed.

[0050] The Z2 axis assembly includes a Z2 axis guide rail 14, a Z2 axis lead screw 15, and a Z2 axis motor 16 mounted on a base 1. The Z2 axis guide rail 14 is parallel to the Z1 axis guide rail 11 and is arranged in a horizontal left-right direction. The Z2 axis motor 16 drives the Z2 axis lead screw 15 to rotate, which is used to assist in axial feed motion and precise adjustment of machining position.

[0051] 2. Saddle.

[0052] The saddle 2 is positioned above the base 1, slidingly engaging with the Z1 axis guide rail 11 on the base 1, and threadedly connected to the Z1 axis lead screw 12. The Z1 axis motor 13 drives the Z1 axis lead screw 12 to rotate, causing the saddle 2 to move horizontally left and right along the Z1 axis guide rail 11, thereby realizing the transverse feed motion of the machine tool.

[0053] The saddle 2 is fixedly equipped with an X-axis guide rail 21, an X-axis lead screw 22, and an X-axis motor 23, which provide guidance and power for the X-axis movement.

[0054] 3. X-axis skateboard.

[0055] The X-axis slide plate 3 is mounted above the saddle 2 and slides in engagement with the X-axis guide rail 21 arranged horizontally along the front-back direction on the saddle 2. It is also threadedly connected to the X-axis lead screw 22. The X-axis motor 23 drives the X-axis lead screw 22 to rotate, which in turn moves the X-axis slide plate 3 along the X-axis guide rail 21 in the front-back direction, thereby realizing the longitudinal feed motion of the machine tool.

[0056] The top of the X-axis slide plate 3 is fixedly mounted with the A2 turntable 4, which provides a mounting base and rotation drive for the rotatable column 5.

[0057] 4. A2 turntable and rotatable column.

[0058] The A2 rotary table 4 is fixedly mounted on the X-axis slide plate 3, and its rotary output end is fixedly connected to the rotatable column 5 to form the A2 axis. The A2 rotary table 4 is used to drive the rotatable column 5 to rotate 180° precisely around the horizontal axis, realizing the automatic switching between the horizontal milling and turning machining mode and the horizontal gear hobbing machining mode. The switching process does not require manual intervention, and the workpiece remains in the same clamping state.

[0059] The rotatable column 5 is a vertical rigid structure, fixedly installed on the rotating platform of turntable A2 4, and rotates synchronously with turntable A2 4. Two independent guide mechanisms are arranged parallel to each other vertically on the side of the rotatable column 5, namely the first vertical guide mechanism and the second vertical guide mechanism, corresponding to the Y1 axis guide rail 51 and the Y2 axis guide rail 52. The Y1 axis guide rail 51 and the Y2 axis guide rail 52, arranged parallel to each other vertically on the side of the rotatable column 5, constitute the Y1 axis and the Y2 axis, respectively.

[0060] The rotatable column 5 is used to support the gear hobbing spindle unit 6 and the oscillating milling spindle unit 7, so that the two spindle units can be raised and lowered independently without interference between them.

[0061] 5. Gear hobbing spindle unit.

[0062] The gear hobbing spindle unit 6 includes upper and lower slide plates 61, A1 turntable 62, B1 axis hobbing spindle 63, and hob 64.

[0063] The upper and lower sliding plates 61 are slidably connected to the Y1 axis guide rail 51 on the rotatable column 5. Driven by the Y1 axis motor and the Y1 axis lead screw, they move vertically up and down, forming the Y1 axis. The A1 turntable 62 is fixedly mounted on the upper and lower sliding plates 61, forming the A1 axis, which drives the B1 axis hob spindle 63 to swing, thereby adjusting the helix angle and installation angle of the hob 64 to adapt to the hobbing of gears with different modules and helix angles. The B1 axis hob spindle 63 is mounted on the A1 turntable 62, forming the B1 axis. The hob 64 is fixedly connected to and driven to rotate by the B1 axis hob spindle 63. In conjunction with the C1 axis indexing and the X / Z / Y1 axis linkage, high-precision horizontal gear hobbing is achieved.

[0064] 6. Swing milling spindle unit.

[0065] The oscillating milling spindle unit 7 has three interchangeable configurations, including:

[0066] (1) Power turret configuration: including upper and lower slide plates 71 and power turret 74. The power turret 74 is mounted on the upper and lower slide plates 71. The power turret 74 has its own cutting power and can realize turning and milling operations.

[0067] (2) Milling and turning spindle configuration: including upper and lower slide plates 71, B2 axis rotary table 72 and milling and turning power spindle 73. The B2 axis rotary table 72 is mounted on the upper and lower slide plates 71, and the milling and turning power spindle 73 is mounted on the B2 axis rotary table 72, providing cutting power and enabling five-axis linkage.

[0068] (3) Electric turret configuration: including upper and lower slide plates 71 and electric turret 75. The electric turret 75 is installed on the upper and lower slide plates 71. The electric turret 75 only has the power to change the tool position and has no cutting power. It can only realize turning.

[0069] The upper and lower sliding plates 71 are slidably connected to the Y2 axis guide rail 52 on the rotatable column 5. Driven by the Y2 axis motor and the Y2 axis lead screw, they move up and down in the vertical direction, forming the Y2 axis.

[0070] The oscillating milling spindle unit 7 can adjust the oscillation angle of the milling cutter according to the machining requirements. It works in conjunction with the X, Z, Y2, C1, and B2 (milling power spindle) to complete five-axis linkage, performing turning machining on the outer diameter, end face, and steps of the workpiece, as well as milling machining on complex curved surfaces, inclined surfaces, and hole systems. It is equipped with a universal tool holder, which can quickly change turning tools, milling cutters, chamfering tools, deburring tools, etc., to adapt to different milling machining processes.

[0071] 7. Turning spindle unit.

[0072] The turning spindle unit 8 includes a C1-axis spindle box 81 and a C1-axis spindle 82.

[0073] The C1 axis spindle box 81 is fixedly installed on one side of the base 1, providing support and a mounting base for the C1 axis spindle 82.

[0074] The C1 axis spindle 82 is coaxially mounted inside the C1 axis spindle box 81 to form the C1 axis, which is used to clamp the workpiece 10 and drive the workpiece 10 to rotate. It also has a high-precision indexing function, providing accurate indexing and positioning for gear hobbing, gear milling, and gear turning.

[0075] The C1 axis adopts a high-precision servo spindle with stepless speed regulation and high-precision indexing function of the C axis. It is equipped with a workpiece chuck and serves not only as the workpiece rotation drive source for turning, but also as the workpiece indexing drive axis for gear hobbing and milling, ensuring the indexing accuracy of gear machining.

[0076] 8. Auxiliary tailstock spindle unit.

[0077] The auxiliary tailstock spindle unit 9 includes a C2 axis spindle box 91 and a C2 axis spindle 92.

[0078] The C2 axis spindle box 91 is mounted on the Z2 axis guide rail 14 of the base 1, slides with the Z2 axis guide rail 14, and is threadedly connected to the Z2 axis lead screw 15. It is driven by the Z2 axis motor 16 to move in the horizontal left and right direction, and is used to adapt to the clamping and support of workpieces 10 of different lengths.

[0079] The C2 axis spindle 92 is coaxially mounted inside the C2 axis spindle box 91 to form the C2 axis. The C2 axis spindle 92 and the C1 axis spindle 82 are coaxially arranged to perform end clamping and support positioning of the workpiece 10, improve the workpiece machining rigidity, and suppress cutting vibration and deformation.

[0080] The auxiliary tailstock spindle unit 9 is equipped with an automatic hydraulic chuck and ejector pin. It is coaxial with the spindle axis of the turning spindle unit 8 and can move freely along the Z-axis. It works in conjunction with the turning spindle unit 8 to support and position both ends of long shaft workpieces, ensuring the rigidity of long shaft workpieces during processing, avoiding workpiece vibration and deformation during processing, and improving processing stability.

[0081] 9. Workpiece.

[0082] Workpiece 10 is a shaft or gear shaft part to be processed. One end is clamped and fixed on the C1 spindle 82, and the other end is supported by the C2 spindle 92, so as to achieve one-time clamping and positioning, and complete all processing steps without disassembly or repositioning.

[0083] In the composite machine tool integrating five-axis linkage milling and horizontal gear hobbing functions of the present invention, the specific parameters of each component are as follows: Z1 axis guide rail 11, Z2 axis guide rail 14, X axis guide rail 21, Y1 axis guide rail 51, and Y2 axis guide rail 52 all adopt high-precision roller linear guide rails, with feed positioning accuracy ≤0.002mm and repeatability ≤0.001mm; A2 rotary table 4 has a rotation positioning accuracy ≤0.005°; A1 rotary table 62 and B2 axis rotary table 72 have an oscillation angle range of -45° to +45°, with an angle adjustment accuracy ≤0.001°; C1 axis spindle 82 adopts a permanent magnet synchronous servo spindle with a stepless speed regulation range of 0-3000r / min and an indexing accuracy ≤0.001°.

[0084] II. Processing mode switching method.

[0085] This invention also provides a method for switching machining modes in a composite machine tool, applied to the aforementioned composite machine tool, with the following specific steps:

[0086] (1) Workpiece clamping: The cylindrical gear shaft blank is clamped as workpiece 10 at the end of the C1 axis spindle 82. The C2 axis spindle box 91 is driven by the Z2 axis motor 16 to move along the Z2 axis guide rail 14, so that the C2 axis spindle 92 presses against the other end of the workpiece 10, thus completing one clamping and positioning.

[0087] (2) Horizontal milling and turning composite machining: The machine tool is in horizontal milling and turning composite mode. If it is configured with a milling and turning spindle, the B2 axis rotary table 72 adjusts the tool posture, and the milling and turning power spindle 73 drives the tool to rotate to complete the machining. If it is configured with a power turret, the power turret 74 drives the tool to rotate to complete the machining. If it is configured with an electric turret, only turning machining is performed.

[0088] The X-axis motor 23, Z1-axis motor 13, and Y2-axis motor work together to feed and complete the turning and milling of the outer circle, end face, and steps of workpiece 10.

[0089] (3) Machining mode switching: The rotating column 5 is driven to rotate 180° by the A2 turntable 4, so that the hobbing spindle unit 6 and the swing milling spindle unit 7 switch working positions, realizing the automatic seamless switching between the horizontal milling and turning mode and the horizontal hobbing mode; the switching process is controlled by the CNC system, the switching time is ≤10s, the workpiece 10 is kept in the first clamping state, and there is no need to reposition.

[0090] (4) Horizontal gear hobbing: A1 turntable 62 adjusts the helix angle and installation angle of hob 64, B1 axis hob spindle 63 drives hob 64 to rotate, and C1 axis spindle 82 indexes, X axis, Z axis and Y1 axis are linked to complete gear hobbing.

[0091] (5) Subsequent finishing: The A2 turntable 4 drives the rotatable column 5 to rotate 180° in the opposite direction. The machine tool switches back to the horizontal turning and milling compound mode. According to the configuration of the currently installed swing turning and milling spindle unit, the corresponding turning, milling, chamfering, deburring and other processing are completed.

[0092] (6) Machining completed: Loosen the clamping structure between spindle 82 of C1 axis and spindle 92 of C2 axis, remove the machined cylindrical gear shaft, and complete the entire machining process.

[0093] This invention discloses a composite machine tool integrating five-axis linkage turning and milling with horizontal gear hobbing functions, enabling all processes to be completed in a single clamping, significantly improving machining accuracy. After the workpiece is clamped once, it does not need to be disassembled and repositioned again, directly completing all processes such as turning, milling, gear hobbing, gear milling, gear turning, chamfering, deburring, and gear grinding, completely avoiding positioning errors caused by multiple clamping, and significantly improving the machining accuracy and dimensional consistency of parts.

[0094] This invention discloses a composite machine tool integrating five-axis linkage milling and turning with horizontal gear hobbing functions. This highly integrated multi-functionality reduces equipment investment costs. By combining milling and turning machining with horizontal gear hobbing into a single machine, it replaces multiple machines such as CNC lathes, machining centers, and dedicated gear hobbing machines, reducing enterprise equipment purchase investment, saving production space, and lowering equipment maintenance and management costs.

[0095] This invention discloses a composite machine tool integrating five-axis linkage milling and turning with horizontal gear hobbing functions. It features precise multi-axis linkage, a wide processing range, and strong versatility. Through a multi-axis motion system, it achieves precise linkage, adapting to the machining of gears with different modules and helix angles. It can complete the milling of complex curved and inclined surfaces, meeting the processing needs of various industries.

[0096] This invention discloses a composite machine tool integrating five-axis linkage milling and turning with horizontal gear hobbing functions, enabling rapid switching of machining modes and significantly improving production efficiency. The machining mode switching is automated through an A2 rotary table driving a rotatable column, with short switching time and no need for manual adjustment of equipment or workpieces; all machining processes are completed in a single setup, eliminating workpiece transfer time between processes, and significantly improving overall production efficiency compared to traditional machining methods.

[0097] This invention discloses a composite machine tool integrating five-axis linkage milling and turning with horizontal gear hobbing functions. Its high-rigidity structural design ensures machining stability and surface quality. The base and rotatable column adopt a high-rigidity structure, and each motion axis uses high-precision guideways. The auxiliary tailstock spindle unit provides end support for long shaft-type workpieces, effectively reducing vibration and deformation during machining. This ensures the rigidity and stability of the machine tool during high-speed, heavy-load machining, and improves the surface quality of machined parts.

[0098] This invention discloses a composite machine tool integrating five-axis linkage milling and turning with horizontal gear hobbing functions, which has a high degree of automation and reduces manual operation costs. Through a CNC system, precise linkage of each axis and automated control of the machining process are achieved. Machining programs can be programmed, stored, and recalled to realize automated processing of batch parts, reducing the intensity of manual operation and intervention, avoiding errors caused by manual operation, and lowering labor costs.

[0099] The above is an exemplary description of the invention. Obviously, the specific implementation of the invention is not limited to the above-described manner. Any non-substantial improvement made using the inventive concept and technical solution of the invention, or the direct application of the inventive concept and technical solution to other situations without modification, is within the protection scope of the invention.

Claims

1. A composite machine tool integrating five-axis linkage turning and milling with horizontal gear hobbing functions, characterized in that, Includes a base (1), a saddle (2), an X-axis slide plate (3), an A2 turntable (4), a rotatable column (5), a gear hobbing spindle unit (6), a swing milling spindle unit (7), a turning spindle unit (8), an auxiliary tailstock spindle unit (9), a workpiece (10), and a multi-axis motion system; The saddle (2) and the base (1) slide in a horizontal left-right direction, and the X-axis slide plate (3) and the saddle (2) slide in a horizontal front-back direction; the A2 turntable (4) connects the X-axis slide plate (3) and the rotatable column (5) and is used to drive the rotatable column (5) to rotate in order to achieve the switching of processing modes; The rotatable column (5) is provided with a first vertical guide mechanism and a second vertical guide mechanism that are independent of each other. The hobbing spindle unit (6) cooperates with the first vertical guide mechanism, and the swing milling spindle unit (7) cooperates with the second vertical guide mechanism. The two move independently without interference. The turning spindle unit (8) and the auxiliary tailstock spindle unit (9) are arranged opposite to each other on the base (1) for clamping, driving and supporting the workpiece (10). The multi-axis motion system includes X-axis, Z-axis, Y1-axis, Y2-axis, A1-axis, A2-axis, B1-axis, B2-axis, C1-axis, and C2-axis, and drives each component to work together to achieve integrated machining of horizontal milling and turning and horizontal gear hobbing.

2. The composite machine tool integrating five-axis linkage milling and horizontal gear hobbing functions according to claim 1, characterized in that, The Z-axis includes a Z1-axis assembly and a Z2-axis assembly. The Z1-axis assembly includes a Z1-axis guide rail (11), a Z1-axis lead screw (12), and a Z1-axis motor (13) mounted on a base (1). The Z1-axis guide rail (11) is arranged in the horizontal left-right direction. The saddle (2) is slidably connected to the Z1-axis guide rail (11) and threadedly engaged with the Z1-axis lead screw (12). The Z1-axis motor (13) drives the Z2-axis to move in the horizontal left-right direction to achieve transverse feed. The Z2-axis assembly includes a Z2-axis guide rail (14), a Z2-axis lead screw (15), and a Z2-axis motor (16) mounted on a base (1). The Z2-axis guide rail (14) is parallel to the Z1-axis guide rail (11) and arranged in the horizontal left-right direction. The Z2-axis motor (16) drives the Z2-axis lead screw (15) to rotate to assist in axial feed motion and precise adjustment of machining position.

3. The composite machine tool integrating five-axis linkage milling and horizontal gear hobbing functions according to claim 1, characterized in that, The X-axis includes an X-axis guide rail (21), an X-axis lead screw (22), and an X-axis motor (23) mounted on the saddle (2). The X-axis guide rail (21) is arranged in the horizontal front-back direction. The X-axis slide plate (3) is slidably connected to the X-axis guide rail (21) and threadedly engaged with the X-axis lead screw (22). It is driven by the X-axis motor (23) to move in the horizontal front-back direction to achieve longitudinal feeding.

4. The composite machine tool integrating five-axis linkage milling and horizontal gear hobbing functions according to claim 1, characterized in that, The Y1 axis and Y2 axis respectively include Y1 axis guide rail (51) and Y2 axis guide rail (52) arranged parallel to each other in the vertical direction on the side of the rotatable column (5). The gear hobbing spindle unit (6) is slidably connected to the Y1 axis guide rail (51) and driven to lift by the Y1 axis motor and the Y1 axis lead screw. The swing milling spindle unit (7) is slidably connected to the Y2 axis guide rail (52) and driven to lift by the Y2 axis motor and the Y2 axis lead screw. The two movements do not interfere with each other.

5. The composite machine tool integrating five-axis linkage turning and milling with horizontal gear hobbing functions according to claim 1, characterized in that, The gear hobbing spindle unit (6) includes upper and lower slide plates (61), an A1 turntable (62), a B1 axis hobbing spindle (63), and a hob (64). The upper and lower slide plates (61) are slidably connected to the Y1 axis guide rail (51). The A1 turntable (62) is fixed on the upper and lower slide plates (61). The B1 axis hobbing spindle (63) is mounted on the A1 turntable (62). The hob (64) is fixedly connected to the B1 axis hobbing spindle (63). The A1 turntable (62) is used to adjust the helix angle and installation angle of the hob (64). The B1 axis hobbing spindle (63) drives the hob (64) to rotate, thereby achieving high-precision horizontal gear hobbing. The A2 axis is an A2 turntable (4), which is used to drive the rotatable column (5) to rotate 180° around the horizontal axis, thereby achieving automatic switching of the processing mode.

6. The composite machine tool integrating five-axis linkage milling and horizontal gear hobbing functions according to claim 1, characterized in that, The oscillating milling spindle unit (7) has three interchangeable configurations, including: (1) Power turret configuration: includes upper and lower slide plates (71) and power turret (74). The power turret (74) is installed on the upper and lower slide plates (71). The power turret (74) has its own cutting power and can realize turning and milling by installing various tools. (2) Configuration of milling and turning spindle: including upper and lower slide plates (71), B2 axis rotary table (72) and milling and turning power spindle (73). The milling and turning power spindle (73) is mounted on the B2 axis rotary table (72), and the B2 axis rotary table (72) is mounted on the upper and lower slide plates (71). The milling and turning power spindle (73) has its own cutting power and can realize turning, milling and five-axis linkage machining. (3) Electric turret configuration: including upper and lower slide plates (71) and electric turret (75). The electric turret is installed on the upper and lower slide plates (71). The electric turret only has the power to change the tool position and no cutting power. It can only realize turning. The upper and lower sliding plates (71) are slidably connected to the Y2 axis guide rail (52); the B2 axis is a B2 axis turntable (72), which exists only in the milling spindle configuration and is used to adjust the tool posture to achieve five-axis linkage machining.

7. The composite machine tool integrating five-axis linkage milling and horizontal gear hobbing functions according to claim 3, characterized in that, The turning spindle unit (8) includes a C1 axis spindle box (81) and a C1 axis spindle (82). The C1 axis spindle box (81) is fixedly installed on the base (1). The C1 axis is the C1 axis spindle (82) and is coaxially installed inside the C1 axis spindle box (81) to drive the workpiece (10) to rotate and achieve indexing motion. The auxiliary tailstock spindle unit (9) includes a C2 axis spindle box (91) and a C2 axis spindle (92). The C2 axis spindle box (91) is installed on the Z2 axis guide rail (14) of the base (1) and is controlled to slide by the Z2 axis motor (16) and the Z2 axis lead screw (15). The C2 axis is the C2 axis spindle (92) and is coaxially installed inside the C2 axis spindle box (91) and is coaxially arranged with the C1 axis spindle (82) to support and position the workpiece (10).

8. A method for switching machining modes on a composite machine tool, applied to the composite machine tool with five-axis linkage turning and milling and horizontal gear hobbing functions as described in any one of claims 1-7, characterized in that, The rotating column (5) is driven to rotate 180° by the A2 turntable (4), so that the hobbing spindle unit (6) and the swing milling spindle unit (7) switch working positions, realizing the automatic seamless switching between the horizontal milling and turning mode and the horizontal hobbing mode; the switching process is controlled by the CNC system, and the workpiece (10) is kept in a single clamping state without repositioning.

9. The method for switching processing modes of a composite machine tool according to claim 8, characterized in that, In the horizontal milling and turning compound mode, the turning, milling, chamfering and deburring of the workpiece (10) are completed according to the configuration type of the installed swing milling and turning spindle unit; in the horizontal gear hobbing mode, gear hobbing is completed by the hob (64) and the C1 axis indexing cooperation.

10. The method for switching processing modes of a composite machine tool according to claim 9, characterized in that, After the gear hobbing is completed, the A2 turntable (4) drives the rotatable column (5) to rotate 180° in the opposite direction to reset, and the machine tool switches back to the horizontal turning and milling compound mode to continue to complete the grinding and finishing of the workpiece (10).

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