Method, system, and medium for spiral bevel gear manufacturing based on six-axis CNC machine tool

Abstract

This invention relates to a method, system, and medium for manufacturing spiral bevel gears based on a six-axis CNC machine tool. The method includes: establishing a three-dimensional geometric model based on the design parameters of the spiral bevel gear; performing tooth surface contact analysis on the spiral bevel gear based on the three-dimensional geometric model to obtain the tooth surface contact analysis results; establishing a multi-coordinate kinematic model based on the six-axis CNC machine tool; mapping the spiral bevel gear machining adjustment parameters to the machine tool coordinate system to generate six-axis linkage CNC machining code; performing full-tooth machining of the spiral bevel gear based on the six-axis linkage CNC machining code and collecting tooth surface machining error information; obtaining compensated machining parameters based on the tooth surface machining error information and tooth surface contact analysis results and feeding them back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, thereby achieving closed-loop optimization. This invention effectively improves the tooth surface machining accuracy, contact matching degree, and transmission stability of spiral bevel gears, ensuring the overall quality of full-tooth machining.

Description

Technical Field

[0001] This invention relates to the field of gear processing technology, and specifically to a method, system, and medium for manufacturing spiral bevel gears based on a six-axis CNC machine tool. Background Technology

[0002] Spiral bevel gears, as a typical spatial meshing transmission element, are widely used in automotive drive axles, aircraft landing gear, construction machinery, and high-end equipment transmission systems due to their advantages such as high load-bearing capacity, smooth transmission, and low noise. The tooth surface of a spiral bevel gear is a complex spatial curved surface, and its geometry is determined by a variety of design parameters. The machining accuracy directly affects the gear's transmission error, load-bearing performance, and service life.

[0003] Currently, the industrial manufacturing of spiral bevel gears mainly relies on specialized CNC machine tools, such as end milling machines and end hobbing machines. These specialized machine tools typically employ specific machine tool structures and dedicated CNC systems, achieving relative movement between the tool and the workpiece through preset kinematic chains, thereby completing the tooth profile machining of the spiral bevel gears.

[0004] Although the aforementioned special-purpose machine tools have developed a relatively mature processing technology system through long-term application, the following shortcomings still exist.

[0005] Firstly, traditional methods for machining spiral bevel gears typically rely on machine tool adjustment parameters for control. These parameters are often highly coupled with the machine tool's structure, making them difficult to directly transfer to general-purpose multi-axis CNC machine tools. With the widespread application of five-axis and six-axis CNC machining centers in industry, machining spiral bevel gears using general-purpose multi-axis CNC machine tools has become an important development direction. However, because spiral bevel gear machining involves multi-degree-of-freedom coupled motions such as tool posture, workpiece rotation angle, and feed path, traditional adjustment parameters are difficult to directly map to the coordinate system of multi-axis CNC machine tools, resulting in complex machining parameter settings and long debugging cycles.

[0006] Secondly, existing spiral bevel gear machining processes mostly employ an open-loop machining method, where machining parameters are set once before machining, and gear quality is evaluated offline after machining. This method struggles to reflect the accumulation of errors and changes in machining status in a timely manner, and is easily affected by factors such as machine tool errors, tool wear, and clamping errors, resulting in insufficient machining consistency and stability. Summary of the Invention

[0007] In view of the above-mentioned defects or deficiencies in the prior art, the present invention proposes a method, system and storage medium for manufacturing spiral bevel gears based on a six-axis CNC machine tool.

[0008] This invention provides a method for manufacturing spiral bevel gears based on a six-axis CNC machine tool, comprising:

[0009] A three-dimensional geometric model is established based on the design parameters of the spiral bevel gear. Based on this model, tooth surface contact analysis is performed on the spiral bevel gear to obtain the results, including the position of the tooth surface contact area, the distribution of contact traces, and the variation law of transmission error. A multi-coordinate kinematic model is established based on a six-axis CNC machine tool, including the machine tool coordinate system, the workpiece coordinate system, and the tool coordinate system. The machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code. After machining the entire spiral bevel gear based on the six-axis linkage CNC machining code, tooth surface machining error information is collected, including tooth surface morphology error, tooth surface contact position deviation, and transmission error deviation. Based on the tooth surface machining error information and the tooth surface contact analysis results, compensated machining parameters are obtained and fed back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, achieving closed-loop optimization.

[0010] In one optional embodiment, the spiral bevel gear is an arc-tooth bevel gear, and the design parameters include module, number of teeth, pitch cone angle, helix angle, tooth surface curvature parameter, and tooth width.

[0011] In one alternative embodiment, the spiral bevel gear is a cycloidal bevel gear, and the tooth profile of the three-dimensional geometric model is described by a cycloidal curve.

[0012] In one alternative implementation, the spiral bevel gear is a quasi-hyperboloid bevel gear, and the multi-coordinate kinematic model includes workpiece axis offset parameters to adapt to transmission scenarios where workpiece axes do not intersect.

[0013] In one optional implementation, based on the tooth surface machining error information and the tooth surface contact analysis results, compensated machining parameters are obtained and fed back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code. Specifically, this includes: compensating the machining parameters based on the tooth surface contact analysis results and the type of the tooth surface machining error information, determining the compensation direction and compensation amount of the machining parameters, and obtaining the compensated machining parameters; and updating the six-axis linkage CNC machining code based on the compensated machining parameters.

[0014] In one optional implementation, the machining parameters are compensated, specifically including: compensating the machine tool pose parameters when the overall position of the tooth surface shifts; adjusting the tool posture parameters when the shape of the tooth surface contact trace changes; and locally correcting the feed parameters when the local error of the tooth surface is significant.

[0015] In one optional implementation, the machining error information of the tooth surface is collected on-site, and key feature points or point cloud data of the tooth surface are collected to calculate the machining error.

[0016] In one optional implementation, the machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code. Specifically, this includes mapping the machining adjustment parameters of the spiral bevel gear to the machine tool coordinate system through the multi-coordinate kinematic model to obtain tool posture parameters, workpiece rotation angle parameters and feed path parameters, and generating the six-axis linkage CNC machining code.

[0017] This invention also proposes a spiral bevel gear manufacturing system based on a six-axis CNC machine tool, comprising: a multi-coordinate system kinematic modeling and CNC code generation module, used to establish a three-dimensional geometric model based on the design parameters of the spiral bevel gear, and to perform tooth surface contact analysis on the spiral bevel gear based on the three-dimensional geometric model to obtain the tooth surface contact analysis results; establishing a multi-coordinate system kinematic model based on the six-axis CNC machine tool, mapping the spiral bevel gear machining adjustment parameters to the machine tool coordinate system, and generating six-axis linkage CNC machining code; a six-axis linkage machining center core module, which performs full-tooth machining of the spiral bevel gear based on the six-axis linkage CNC machining code; an on-machine measurement and control submodule, which collects tooth surface machining error information; and a closed-loop optimization and parameter compensation module, which obtains compensated machining parameters based on the tooth surface machining error information and tooth surface contact analysis results and feeds them back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, thereby achieving closed-loop optimization.

[0018] The present invention also proposes a storage medium, characterized in that it stores a computer program, which, when executed by a processor, implements any of the spiral bevel gear manufacturing methods based on a six-axis CNC machine tool.

[0019] The beneficial technical effects of this invention are as follows: by relying on a six-axis CNC machine tool to construct a multi-coordinate kinematic model and realize six-axis linkage machining, combined with tooth surface contact analysis and machining error acquisition to carry out closed-loop optimization, accurately compensate machining parameters, effectively improve the machining accuracy, contact matching degree and transmission stability of spiral bevel gear tooth surface, and ensure the overall quality of full-tooth machining. Attached Figure Description

[0020] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0021] Figure 1 A flowchart illustrating a method for manufacturing spiral bevel gears based on a six-axis CNC machine tool, as provided in an embodiment of the present invention;

[0022] Figure 2 A schematic diagram of a three-dimensional geometric model of a spiral bevel gear for a spiral bevel gear manufacturing method based on a six-axis CNC machine tool provided in an embodiment of the present invention;

[0023] Figure 3A schematic diagram illustrating the spatial relationship between the tool coordinate system, workpiece coordinate system, and machine tool coordinate system in a spiral bevel gear manufacturing method based on a six-axis CNC machine tool, provided in an embodiment of the present invention.

[0024] Figure 4 A schematic diagram of the contact analysis of the tooth surface of a spiral bevel gear in a spiral bevel gear manufacturing method based on a six-axis CNC machine tool provided in an embodiment of the present invention;

[0025] Figure 5 The flowchart illustrates a closed-loop manufacturing method for a full-tooth spiral bevel gear based on a six-axis CNC machine tool, as provided in an embodiment of the present invention. Detailed Implementation

[0026] Specialized spiral bevel gear machining machines are complex in structure and expensive to manufacture. They also have high requirements for machine tool precision, assembly and adjustment levels, and maintenance conditions, making it difficult to meet the flexible needs of small-batch, multi-variety gear processing. Furthermore, these machine tools and their core CNC systems have long relied on imports. The closed nature of key functional modules and machining algorithms restricts the independent optimization and expansion of processing techniques, resulting in significant technological barriers and supply chain risks.

[0027] Current spiral bevel gear machining processes mostly employ an open-loop machining method, where machining parameters are set once before machining, and gear quality is evaluated offline after machining. This method struggles to reflect the accumulation of errors and changes in machining conditions in a timely manner, and is easily affected by factors such as machine tool errors, tool wear, and clamping errors, resulting in insufficient machining consistency and stability.

[0028] In the field of precision gear manufacturing, Tooth Contact Analysis (TCA) and Loaded Tooth Contact Analysis (LTCA) have been widely used in gear design and performance evaluation. However, in existing technologies, the results of Tooth Contact Analysis are mostly used in the design verification stage, lacking effective linkage with the actual machining process, making it difficult to provide real-time guidance and correction for machining parameters.

[0029] Therefore, how to realize the full-tooth machining of spiral bevel gears on a general-purpose six-axis CNC machine tool platform, and organically combine gear design, machining simulation, in-machine inspection and machining parameter optimization to build a closed-loop control mechanism for the machining process, is a technical problem that urgently needs to be solved in the field of CNC manufacturing of spiral bevel gears.

[0030] The following is in conjunction with the appendix Figures 1 to 5The present application will be further described in detail with reference to the embodiments. It is understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. It should also be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0031] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0032] Please refer to Figure 1 This is a schematic diagram illustrating the design process of a controllable six-axis linkage machining center. This machining center serves as the implementation platform for the method of this invention. By introducing the concept of multi-degree-of-freedom linkage control during the structural design phase, it provides the hardware foundation for the full-gear machining of helical bevel gears on general-purpose CNC machine tools.

[0033] This invention provides a method for manufacturing spiral bevel gears based on a six-axis CNC machine tool, comprising the following steps:

[0034] Step S101: Establish a three-dimensional geometric model based on the design parameters of the spiral bevel gear.

[0035] Step S103: Perform tooth surface contact analysis on the spiral bevel gear based on the three-dimensional geometric model to obtain the tooth surface contact analysis results. The tooth surface contact analysis results include the position of the tooth surface contact area, the distribution of contact traces, and the variation law of transmission error.

[0036] Step S105: Establish a multi-coordinate kinematic model based on a six-axis CNC machine tool. The multi-coordinate system includes the machine tool coordinate system, the workpiece coordinate system, and the tool coordinate system.

[0037] Step S107: Map the spiral bevel gear machining adjustment parameters to the machine tool coordinate system to generate six-axis linkage CNC machining code.

[0038] Step S109: After machining the spiral bevel gear using the six-axis linkage CNC machining code, collect the tooth surface machining error information, which includes tooth surface shape error, tooth surface contact position deviation, and transmission error deviation.

[0039] Step S1011: Based on the tooth surface machining error information and tooth surface contact analysis results, the compensated machining parameters are obtained and fed back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code and realize closed-loop optimization.

[0040] In this embodiment, based on the design parameters of the spiral bevel gear, a three-dimensional geometric model of the spiral bevel gear is established using parametric modeling. Tooth surface contact analysis is performed on the tooth surface to obtain the location of the tooth surface contact area, the shape of the contact trace, and the distribution characteristics of transmission errors, providing a theoretical basis for subsequent machining parameter setting and optimization. For example... Figure 3 As shown, the meshing relationship of spiral bevel gears can be described by meshing theory. This theory is used to analyze the position of the tooth surface contact area, the shape of the contact trace, and the variation law of transmission error during the meshing process of the gear pair, providing a theoretical basis for tooth surface contact analysis and machining parameter optimization.

[0041] Based on the structure of a six-axis CNC machine tool, tool coordinate systems, workpiece coordinate systems, and machine tool coordinate systems are established separately. Homogeneous coordinate transformation is used to describe the spatial relationships between these coordinate systems, forming a complete multi-coordinate kinematic model to describe the spatial relative motion between the tool and the workpiece. The six-axis CNC machine tool includes three linear motion axes and three rotary motion axes. Through the coordinated control of these axes, multi-degree-of-freedom spatial relative motion between the tool and the workpiece is achieved, providing the necessary motion conditions for the forming and machining of complex tooth surfaces of spiral bevel gears.

[0042] To achieve precise forming and machining of spiral bevel gears on a six-axis CNC machine tool, this invention establishes a unified definition principle for the machine tool coordinate system, workpiece coordinate system, and tool coordinate system when constructing a multi-coordinate kinematic model.

[0043] The machine tool coordinate system is used to describe the spatial positional relationship of each motion axis of a six-axis CNC machine tool, and its coordinate axis direction is defined according to the general coordinate system standard for CNC machine tools. The workpiece coordinate system is established with the axis and end face of the spiral bevel gear blank as the reference, and is used to describe the spatial posture of the gear during the machining process. The tool coordinate system is established with the geometric center of the tool and the direction of the tool axis as the reference, and is used to describe the posture changes of the tool and the cutting path.

[0044] By introducing homogeneous coordinate transformation to uniformly describe the spatial relationships between the aforementioned coordinate systems, the complex spatial relative motion between the tool and the workpiece can be decomposed into a combination of multiple basic motion units. This multi-coordinate kinematic model can fully reflect the influence of each motion axis in a six-axis CNC machine tool on the tool's posture, position, and feed path, providing a unified mathematical description framework for subsequent machining parameter mapping and CNC code generation.

[0045] By using a multi-coordinate kinematic model, the traditional machining adjustment parameters used in the machining of spiral bevel gears are mapped to the coordinate system of a six-axis CNC machine tool to obtain the corresponding six-axis linkage machining parameters.

[0046] Unlike traditional dedicated spiral bevel gear machining tools that rely on fixed kinematic chains, the multi-coordinate kinematic model constructed in this invention does not depend on a specific machine tool structure. As long as the machine tool has the ability to realize multi-degree-of-freedom relative motion between the tool and the workpiece, this model can be used to complete the mapping of machining parameters and machining control, thereby significantly improving the versatility and adaptability of the machining method.

[0047] To facilitate the description of the spatial relative motion between the tool and the workpiece, this invention employs a homogeneous coordinate transformation to uniformly express the kinematic model across multiple coordinate systems. The spatial position of any point in the tool coordinate system can be mapped to the workpiece coordinate system through the following relationship:

[0048] ;

[0049] in, This represents the coordinates of a point in the tool coordinate system. This represents the coordinates of the corresponding point in the workpiece coordinate system. This represents the homogeneous transformation matrix from the tool coordinate system to the machine coordinate system. This represents the homogeneous transformation matrix from the machine tool coordinate system to the workpiece coordinate system.

[0050] By using the above homogeneous coordinate transformation relationship, the displacement and rotation angle of each motion axis of a six-axis CNC machine tool can be uniformly incorporated into the same mathematical description framework, thereby achieving precise control of the tool's posture and position.

[0051] The machine tool adjustment parameters used in the traditional machining process of spiral bevel gears are mapped to the coordinate system of a six-axis CNC machine tool through a multi-coordinate kinematic model, generating corresponding six-axis linkage CNC machining parameters, and automatically generating CNC machining code accordingly.

[0052] In traditional spiral bevel gear machining, tooth surface forming is typically controlled by adjusting machine tool parameters. These parameters are often strongly correlated with the structure and kinematic chain of specialized machine tools, making them difficult to apply directly to general-purpose six-axis CNC machine tools. Therefore, this invention reconstructs and maps traditional machining adjustment parameters using a multi-coordinate kinematic model.

[0053] In the parameter mapping process, this invention abstracts the traditional spiral bevel gear machining adjustment parameters into a parameter vector form and maps them to the motion axis parameter vector of a six-axis CNC machine tool. The relationship can be expressed as follows:

[0054] ;

[0055] in, This represents a vector of traditional machining adjustment parameters, including tool mounting angle, tool tilt angle, workpiece rotation angle, and feed parameters. This indicates the displacement and rotation of each motion axis of a six-axis CNC machine tool. This is a parameter mapping function established based on a multi-coordinate system kinematic model.

[0056] Through this mapping relationship, machining adjustment parameters that originally relied on dedicated machine tool structures can be converted into linkage control parameters that can be directly executed by a six-axis CNC machine tool.

[0057] Specifically, traditional machining adjustment parameters include tool mounting angle, tool tilt angle, workpiece rotation angle, and feed parameters. These parameters are coupled in a fixed mechanism within a dedicated machine tool. In this invention, by converting these adjustment parameters into displacement and rotation values ​​of each motion axis of a six-axis CNC machine tool, equivalent expressions of machining parameters are achieved across different machine tool platforms.

[0058] This mapping method transforms the tooth surface forming process, which originally relied on a dedicated machine tool structure, into a linkage control process that can be directly executed by a six-axis CNC machine tool, thereby enabling the full-tooth machining of spiral bevel gears on a general-purpose six-axis CNC machine tool. This parameter mapping process is independent of specific gear types and is applicable to spiral bevel gears, cycloidal bevel gears, and quasi-hypoid bevel gears, demonstrating the versatility of the method.

[0059] Based on CNC machining code, the full gear machining of spiral bevel gears is completed on a six-axis CNC machine tool, including end-face milling or end-face hobbing. For example... Figure 4 As shown, this invention constructs a closed-loop manufacturing method for full-tooth spiral bevel gears based on a six-axis CNC machine tool, including steps such as design modeling, tooth surface contact analysis, machining parameter mapping, full-tooth machining, in-machine inspection, and parameter compensation optimization, forming a complete closed-loop manufacturing system.

[0060] Full-gear machining includes end-face milling or end-face hobbing. During or after machining, key feature data or point cloud data of the spiral bevel gear tooth surface are acquired through machine inspection, and the tooth surface machining error information is calculated accordingly.

[0061] By combining the tooth surface contact analysis results with machining error information, the machining parameters of the six-axis CNC machine tool are compensated and corrected, and the corrected machining parameters are fed back to the CNC system for subsequent machining, thereby realizing closed-loop optimized manufacturing of the spiral bevel gear machining process.

[0062] This method relies on a six-axis CNC machine tool to construct a multi-coordinate kinematic model and realize six-axis linkage machining. It combines tooth surface contact analysis and machining error acquisition to carry out closed-loop optimization, accurately compensate machining parameters, effectively improve the machining accuracy, contact matching degree and transmission stability of spiral bevel gear tooth surface, and ensure the overall quality of full-tooth machining.

[0063] Based on the tooth surface machining error information and tooth surface contact analysis results, the compensated machining parameters are obtained and fed back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code. The specific steps include the following:

[0064] Step S10111: Based on the tooth surface contact analysis results and the type of tooth surface machining error information, compensate the machining parameters, determine the compensation direction and compensation amount of the machining parameters, and obtain the compensated machining parameters.

[0065] Step S10113: Update the six-axis linkage CNC machining code based on the compensated machining parameters.

[0066] By combining the tooth surface contact area location, contact trace distribution, and transmission error variation patterns obtained from tooth surface contact analysis, and simultaneously matching the tooth surface machining error information with corresponding tooth surface morphology errors, tooth surface contact position deviations, and transmission error deviation types, directional compensation analysis is conducted on the machining adjustment parameters of a six-axis CNC machine tool. This accurately determines the compensation direction and amount for each machining parameter, and after parameter calibration, the compensated machining parameters are obtained. The compensation process combines the results of tooth surface contact analysis with the types of machining errors, achieving directional and precise compensation of machining parameters. This effectively avoids blind parameter adjustments, improves the targeting and accuracy of machining parameter compensation, precisely targets the root causes of tooth surface machining errors at the parameter level, and efficiently corrects various errors such as tooth surface morphology, contact position, and transmission.

[0067] Based on the compensated machining parameters, the six-axis CNC machining code is specifically modified and updated to ensure a complete match between the CNC machining code's instruction parameters and the compensated machining parameters. Simultaneously, the updated CNC machining code is synchronized to the CNC system of the six-axis CNC machine tool, achieving coordinated updates of machining parameters and CNC machining code. Updating the CNC machining code based on the compensated machining parameters ensures a high degree of compatibility between the CNC machining code's instruction parameters and the compensation parameters. This guarantees a complete match between the machining instructions executed by the six-axis CNC machine tool and the compensation requirements, avoiding secondary machining errors caused by parameter-code mismatches and improving the adaptability and effectiveness of the CNC machining code. It enables coordinated linkage between machining parameter compensation and CNC machining code updates, allowing the six-axis CNC machine tool to accurately execute the compensated machining parameters based on the updated code. This ensures rapid and effective implementation of compensation measures, efficiently correcting tooth surface machining errors and significantly improving the tooth surface machining accuracy, tooth surface contact matching, and transmission stability of spiral bevel gears. The parameter compensation and code update process does not require additional adjustments to the machine tool hardware. Error compensation is achieved solely through software-level parameter calibration and code correction, simplifying the tooth surface error correction process, improving the execution efficiency of machining closed-loop optimization, reducing the operational cost of error correction, and ensuring the continuity and stability of six-axis linkage machining.

[0068] Machining parameter compensation includes machine tool pose compensation, tool posture compensation, and feed parameter compensation. Specifically, compensation for machining parameters includes: compensating for machine tool pose parameters when the overall tooth surface position shifts; adjusting tool posture parameters when the tooth surface contact trace shape changes; and locally correcting feed parameters when there are significant local errors on the tooth surface. Matching corresponding machine tool pose, tool posture, and feed parameter compensation methods to different types of tooth surface machining errors—compensating for overall tooth surface position shifts with machine tool pose parameters, adjusting tool posture parameters for changes in contact trace shape, and correcting feed parameters for significant local errors—allows for precise matching and targeted compensation of machining parameter error types and compensation methods. This significantly improves the targeting and accuracy of parameter compensation, efficiently correcting machining errors related to tooth surface position, contact trace, and local morphology, avoiding the limitations of single compensation methods. It precisely eliminates tooth surface machining errors from multiple dimensions, significantly improving the machining accuracy and contact matching of spiral bevel gears, and further ensuring gear transmission stability.

[0069] In-machine acquisition of tooth surface machining error information, along with the collection of key feature points or point cloud data of the tooth surface for error calculation, eliminates the need to move the workpiece to external inspection equipment. This significantly shortens the overall cycle of error acquisition and analysis, ensuring the continuity of the machining process. Furthermore, the high-precision acquisition of key feature points and point cloud data provides comprehensive and accurate raw data support for machining error calculation, ensuring that the calculated results more closely reflect the actual machining conditions. This improves the accuracy and reliability of error judgment, laying a solid data foundation for subsequent precise compensation of machining parameters.

[0070] The machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code, specifically including:

[0071] The machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system through a multi-coordinate kinematic model to obtain the tool posture parameters, workpiece rotation angle parameters and feed path parameters, and generate six-axis linkage CNC machining code.

[0072] By using a multi-coordinate kinematic model, the machining adjustment parameters of spiral bevel gears are accurately mapped to the machine tool coordinate system. This simultaneously transforms core machining parameters such as tool posture, workpiece rotation angle, and feed path, generating six-axis CNC machining code. This ensures the compatibility of machining adjustment parameters with the machine tool coordinate system, guaranteeing kinematic coordination and matching of parameters across multiple coordinate systems. Furthermore, it achieves integrated and coded output of relevant parameters for the tool, workpiece, and feed path, allowing the coordinated motion of the six-axis CNC machine tool to precisely match the machining requirements of the spiral bevel gears. This effectively avoids machining deviations caused by parameter mapping errors or improper coordinate system adaptation, significantly improving the accuracy and reliability of CNC machining code generation. It provides precise and coordinated instruction support for high-precision full-tooth machining of spiral bevel gears, ensuring that the tooth surface morphology, contact characteristics, and transmission performance meet design requirements.

[0073] Spiral bevel gears are any one of arc bevel gears, cycloidal bevel gears, or quasi-hyperboloid bevel gears.

[0074] Furthermore, the spiral bevel gear is an arc-tooth bevel gear, and its design parameters include module, number of teeth, pitch cone angle, helix angle, tooth surface curvature parameters, and tooth width.

[0075] A closed-loop manufacturing method for spiral bevel gears based on a six-axis CNC machine tool is proposed. Using spiral bevel gears as the machining object, full-tooth machining is performed on a general-purpose six-axis CNC machine tool platform, and a complete manufacturing closed loop is constructed. First, a three-dimensional geometric model of the gear is established based on the design parameters of the spiral bevel gear. These design parameters include, but are not limited to, module, number of teeth, pitch cone angle, helix angle, tooth surface curvature parameters, and tooth width. Then, a parametric modeling method is used to generate the tooth surface geometric model of the spiral bevel gear.

[0076] Based on this, tooth surface contact analysis was performed on the spiral bevel gear to obtain the position of the tooth surface contact area, the distribution of contact traces, and the variation law of transmission error during the meshing process. The tooth surface contact analysis results are used to guide the initial setting of subsequent machining parameters and the determination of compensation direction.

[0077] Based on the adopted six-axis CNC machine tool structure, machine tool coordinate system, workpiece coordinate system, and tool coordinate system are established respectively. Among them, the machine tool coordinate system is used to describe the spatial positional relationship of each motion axis of the machine tool, the workpiece coordinate system is used to describe the position and posture of the spiral bevel gear blank, and the tool coordinate system is used to describe the spatial posture and motion path of the tool.

[0078] By establishing the spatial mapping relationship between the above coordinate systems through homogeneous coordinate transformation, a complete multi-coordinate kinematic model is constructed to describe the spatial relative motion between the tool and the workpiece.

[0079] In the traditional machining process of spiral bevel gears, the tooth surface forming is usually controlled by adjusting machine tool parameters. In this embodiment, the traditional spiral bevel gear machining adjustment parameters are mapped to the coordinate system of a six-axis CNC machine tool through a multi-coordinate kinematic model, resulting in the corresponding tool posture parameters, workpiece rotation angle parameters, and feed path parameters.

[0080] Based on the above mapping relationship, six-axis linkage CNC machining code is automatically generated, enabling the tool to complete the full tooth machining of spiral bevel gears on a six-axis CNC machine tool.

[0081] like Figure 5 As shown, the remote diagnostic and in-machine inspection module of the machine tool can monitor the tooth surface machining status in real time or near real time during the machining process of spiral bevel gears, obtain tooth surface machining error information, and provide data support for machining parameter compensation and correction.

[0082] During or after the machining of spiral bevel gears, the machining error is calculated by collecting key feature points or point cloud data of the tooth surface using a machine inspection device.

[0083] Based on the aforementioned tooth surface contact analysis results, the machining error is analyzed to determine the compensation direction and amount of the machining parameters. The compensated machining parameters are then fed back to the CNC system for subsequent machining, thus forming a closed-loop optimization process for the machining of spiral bevel gears.

[0084] The tooth surface machining error information obtained by in-machine inspection can include various forms such as tooth surface shape error, tooth surface contact position deviation, and transmission error deviation. For different types of error information, this invention distinguishes the objects to be compensated for machining parameters.

[0085] When the detection results indicate that the overall position of the tooth surface has shifted, compensation and correction can be made by adjusting the machine tool pose parameters; when the shape of the tooth surface contact trace changes, compensation can be made by adjusting the tool attitude parameters; when the local error of the tooth surface is significant, local correction can be made by adjusting the feed parameters. Through these methods, the correspondence between machining errors and compensation parameters is established.

[0086] During the closed-loop compensation process, this invention represents the tooth surface error information obtained by machine detection as an error vector. The corresponding processing parameter compensation amount is determined according to the error type, and the relationship can be expressed as follows:

[0087] ;

[0088] in, This indicates the test results for tooth surface morphology errors, contact position deviations, or transmission error deviations. This indicates the corresponding processing parameter compensation amount. This is the compensation function.

[0089] The above compensation process can be completed after one machining operation, or it can be gradually optimized through multiple detections and compensation iterations, thereby forming a multi-round closed-loop machining process to improve the machining accuracy and consistency of spiral bevel gears.

[0090] Furthermore, the spiral bevel gear is a cycloidal bevel gear, and the tooth profile of the three-dimensional geometric model is described by a cycloidal curve.

[0091] The closed-loop manufacturing method of cycloidal bevel gears based on a six-axis CNC machine tool uses cycloidal bevel gears as the machining object. Its overall process is the same as that of the first implementation method. The difference lies in the specific expression of the tooth surface geometric characteristics and machining parameters.

[0092] Based on the design parameters of the cycloidal bevel gear, a three-dimensional tooth surface model of the cycloidal bevel gear is established. The tooth surface model uses cycloidal curves to describe the tooth profile, and its tooth surface geometry differs from that of the spiral bevel gear.

[0093] By analyzing tooth surface contact, the characteristics of contact area distribution and transmission error variation of cycloidal bevel gears during meshing are obtained, providing a basis for setting and compensating machining parameters.

[0094] In the machining process of cycloidal bevel gears, the machining adjustment parameters corresponding to the cycloidal tooth profile are mapped to the coordinate system of a six-axis CNC machine tool through a multi-coordinate kinematic model, so as to realize the coordinated movement between the tool and the workpiece.

[0095] Based on the mapped machining parameters, the corresponding six-axis linkage CNC machining code is generated to realize the full-tooth machining of cycloidal bevel gears.

[0096] By obtaining machining error information of the cycloidal bevel gear tooth surface through machine inspection, and combining the tooth surface contact analysis results, the machining parameters are compensated and corrected to achieve closed-loop control of the cycloidal bevel gear machining process.

[0097] Furthermore, the spiral bevel gear is a quasi-hyperboloid bevel gear, and the multi-coordinate kinematic model includes workpiece axis offset parameters to adapt to transmission scenarios where workpiece axes do not intersect.

[0098] The closed-loop manufacturing method for quasi-hyperboloid bevel gears based on a six-axis CNC machine tool uses quasi-hyperboloid bevel gears as the machining object and is suitable for transmission scenarios where the workpiece axes do not intersect.

[0099] Based on the design parameters of the quasi-hyperboloid bevel gear, a three-dimensional model of the gear is established. Due to the offset of the workpiece axis, the tooth surface geometry and contact relationship of the quasi-hyperboloid bevel gear are more complex.

[0100] By analyzing tooth surface contact, the contact area distribution, contact trace morphology, and transmission error characteristics of quasi-hyperboloid bevel gears are obtained, providing a basis for setting and compensating machining parameters.

[0101] To address the spatial offset characteristics of quasi-hyperboloid bevel gears, a workpiece axis offset parameter is introduced into the multi-coordinate kinematic model, enabling the tool and workpiece to achieve coordinated spatial movement on a six-axis CNC machine tool.

[0102] Using this kinematic model, the machining parameters of the quasi-hyperboloid bevel gear are mapped to the coordinate system of a six-axis CNC machine tool, enabling the full-tooth machining of the quasi-hyperboloid bevel gear.

[0103] In the machining process of quasi-hyperboloid bevel gears, tooth surface error information is obtained through machine inspection, and the machining parameters are compensated and corrected in combination with the tooth surface contact analysis results, forming a closed-loop manufacturing process for quasi-hyperboloid bevel gears.

[0104] Closed-loop manufacturing processes enable the collection, transmission, and analysis of processing data through industrial networks or industrial cloud platforms.

[0105] This universal closed-loop manufacturing process enables high-precision machining of various types of spiral bevel gears on the same six-axis CNC machine tool platform, demonstrating the versatility and scalability of the method of this invention.

[0106] It should be noted that although spiral bevel gears, cycloidal bevel gears, and quasi-hyperboloid bevel gears differ in tooth surface geometry and contact form, their machining processes can all be reduced to the problem of spatial relative motion control between the tool and the workpiece.

[0107] The closed-loop manufacturing method based on a six-axis CNC machine tool proposed in this invention incorporates the machining processes of different types of spiral bevel gears into the same technical framework through a unified multi-coordinate kinematic model and machining parameter mapping method. Only a few parameters need to be adjusted for specific gear types to complete the corresponding full-gear machining. This further demonstrates the versatility and scalability of the method in different spiral bevel gear machining scenarios.

[0108] like Figure 2 The diagram shows the technical flow chart for the intelligent design and verification of modular machine tools. It fully presents the entire technical path from scheme design to performance testing, and embodies the design concepts of digitalization, modularization and intelligence.

[0109] 1. Machine tool overall structure design, supported by a parametric model library of structural components, a modular standard parts library, and a machine tool topology database, combined with the overall machine structure scheme, outputs the parameters of the overall machine and supporting structures, standard parts selection, and topology selection, providing basic input for subsequent modeling.

[0110] 2. Modular machine tool twin model construction: Based on structural, algorithm and control models, an equipment twin containing multiple component models is constructed. By defining the autonomous operation criteria and construction mechanism of the equipment twin, an autonomous twin agent is generated to realize the digital mapping of the physical entity of the machine tool.

[0111] 3. Dynamic characteristic analysis of key component models: Based on data knowledge from the entire equipment operation and maintenance process, analyze the consistency characteristics of component models and twin behaviors, dynamically construct component twin behaviors, and ensure that the digital model can accurately reflect the operating status and evolution law of physical components.

[0112] 4. Machine tool twin behavior consistency evaluation: Conduct behavior consistency evaluation at multiple levels from component model to equipment twin, including the consistency of behavior between component model and equipment twin, real-time consistency between calculated data and monitoring data, consistency of multi-level twins in equipment scenarios, and establish an evaluation criterion system for autonomous twin construction.

[0113] 5. Simulation analysis and multi-objective testing: Through simulation analysis, the dynamic performance of the machine tool is continuously optimized. The twin data and model knowledge are iteratively input into the simulation model to approximate the design target. Then, through multi-objective model functional testing, the function and performance of the equipment twin in multi-task scenarios are verified, and finally an autonomous twin construction methodology system is formed.

[0114] like Figure 3 The diagram shows a technical research process based on the reference point-based spiral bevel gear meshing theory.

[0115] The overall research is divided into two core branches, both of which ultimately lead to the experimental verification stage.

[0116] The first branch is the research on the theory and method of lattice-based full-process forming: taking gear design parameters as input, we first carry out the research on the processing principle of lattice-based full-process forming, and then construct the large gear cutting model in sequence. We solve the point normal formula and curvature of the tooth surface of the large and small gears through algorithms, further derive the small gear production cone parameters and establish the small gear cutting model; at the same time, we combine the surface interference check method to finally output the machine tool adjustment parameters and cutter head parameters.

[0117] The second branch focuses on the theoretical research of the inclination full roll cutting and inclination half roll cutting methods for austenitic spiral bevel gears. First, it conducts theoretical research on the geometric design of austenitic spiral bevel gears and the design of austenitic cutting tools. In the milling adjustment calculation module, combining the blank installation positioning parameters, tool parameters, cutter head installation parameters, and initial tooth profile values, it completes the calculation of milling profile parameters and the solution of the cutter spindle inclination angle, thereby correcting the cutter head installation parameters and tooth profile angle. Subsequently, it solves for the relative curvature parameters and instantaneous contact ellipse of the meshing tooth surface, and determines whether the requirements are met by using the contact area length coefficient. If not, it returns to adjustment; if it meets the requirements, it outputs the machine tool adjustment parameters and cutter head parameters. Simultaneously, it also needs to perform cutter head interference and secondary cutting checks.

[0118] The parameters output from both branches are fed into the virtual machining process of the spiral bevel gear, followed by virtual rolling inspection. Finally, the closed-loop verification of the entire technical process is completed through a cutting experiment.

[0119] This invention also proposes a spiral bevel gear manufacturing system based on a six-axis CNC machine tool, comprising:

[0120] The multi-coordinate system kinematic modeling and CNC code generation module is used to establish a three-dimensional geometric model based on the design parameters of the spiral bevel gear, and to perform tooth surface contact analysis on the spiral bevel gear based on the three-dimensional geometric model to obtain the tooth surface contact analysis results. Based on a six-axis CNC machine tool, a multi-coordinate system kinematic model is established, and the machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code.

[0121] like Figure 4 The diagram shows a closed-loop manufacturing system from design to finished product inspection.

[0122] 1. In the gear design and modeling stage, the parametric design of the gear is completed based on professional software, and core data such as tooth surface topology are generated simultaneously.

[0123] The meshing characteristics were verified by TCA (tooth surface contact analysis), and a 3D model was completed to provide an accurate digital model for subsequent machining.

[0124] 2. In the machining simulation and execution phase, the 3D model is imported for machining simulation, simulating the tool path and cutting process to proactively avoid risks such as interference and overcutting. After successful simulation verification, G-code is generated to drive the CNC machine tool to complete the actual machining.

[0125] 3. In the inspection and quality verification stage, equipment such as a coordinate measuring machine is used to perform precision inspection on the finished gears, obtaining key error data such as tooth pitch, tooth profile, and tooth direction. Based on the inspection data, a quality analysis report is generated to determine whether the product is qualified.

[0126] 4. Parameter optimization closed loop: If the product is unqualified, the error data will be fed back to the parameter optimization module.

[0127] By optimizing process parameters, modeling errors, and analyzing their origins, the machining scheme is iteratively corrected to form a closed loop of "design-machining-inspection-optimization," thereby continuously improving the precision and stability of gear machining.

[0128] The core module of the six-axis linkage machining center performs full-tooth machining of spiral bevel gears based on six-axis linkage CNC machining code;

[0129] The on-machine measurement and control submodule collects tooth surface machining error information;

[0130] The closed-loop optimization and parameter compensation module obtains the compensated machining parameters based on the tooth surface machining error information and tooth surface contact analysis results, and feeds them back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, thereby realizing closed-loop optimization.

[0131] The core module of the six-axis linkage machining center includes a six-axis CNC machine tool body and supporting spindles, tool magazines, and workpiece clamping mechanisms. The core unit of the six-axis linkage machining center is responsible for executing the six-axis linkage CNC machining code to complete the full-tooth machining of spiral bevel gears.

[0132] Functional component monitoring submodule: Deploys sensors, probes and other devices to monitor fault information such as lead screw loosening, bearing failure, spindle vibration and tool defects in real time.

[0133] Signal acquisition submodule: Acquires raw physical signals such as PLC input / output angles, load values ​​of each axis, and program execution blocks to provide data support for subsequent analysis.

[0134] Embedded on-machine measurement and control submodule: performs preliminary processing on the acquired signals, simultaneously acquires key feature points / point cloud data of the tooth surface, and calculates tooth surface machining errors (such as shape errors, contact position deviations, etc.).

[0135] Independent monitoring subsystem: Independently monitors the status of key machine tool components to ensure the stability of the machining process.

[0136] The closed-loop optimization and parameter compensation module combines the tooth surface contact analysis results (contact area position, contact trace, transmission error) and tooth surface machining error information to directionally compensate for machine tool pose, tool posture or feed parameters, and update CNC machining code to achieve closed-loop optimization of machining accuracy.

[0137] The remote diagnostics and data management module includes:

[0138] Data transmission submodule: Following a unified remote transmission protocol, it securely uploads data to the enterprise network via a gateway / firewall.

[0139] Remote diagnostics submodule: Based on the fault diagnosis model, it performs in-depth analysis of equipment status to achieve remote real-time control.

[0140] Data backup submodule: Synchronously backs up processing data and status data to a remote server to ensure data security and traceability.

[0141] This system constructs a complete closed-loop monitoring system from bottom-level signal acquisition to remote intelligent diagnosis, which is divided into four core levels and can realize the full life cycle status control of a six-axis linkage machining center.

[0142] At the functional component fault monitoring layer, the system focuses on monitoring fault signs of core functional components such as loose leadscrews, bearing failures, spindle vibrations, and tool defects. It also simultaneously collects raw physical signals of equipment operation, such as PLC input / output angles, load values ​​of each axis, and program numbers and blocks, to provide basic data support for subsequent status analysis.

[0143] In the original physical signal acquisition layer, various sensors, probes and other signal acquisition devices are deployed in key parts of the six-axis linkage machining center to capture physical quantities such as vibration, load and position during equipment operation in real time, and transmit the signals to the on-machine monitoring unit to realize real-time perception of the equipment's operating status.

[0144] In the on-machine online and offline monitoring layers, the embedded on-machine online measurement and control unit works in conjunction with the independent monitoring subsystem for key machine tool components to perform preliminary processing and analysis of the acquired signals. Data follows a unified remote transmission protocol standard and is securely transmitted through a gateway / firewall to ensure data integrity and security.

[0145] At the remote fault diagnosis and analysis layer, pre-processed data is uploaded to the enterprise network and equipment management information network, and simultaneously backed up to the remote data backup server. The remote fault diagnosis center, relying on fault diagnosis models, performs in-depth analysis and intelligent diagnosis of equipment status. Combined with the equipment status monitoring network, it achieves remote real-time control of the machining center's operating status, ultimately forming a complete closed loop of "signal acquisition—on-machine monitoring—remote diagnosis," effectively ensuring the stable and efficient operation of the six-axis linkage machining center.

[0146] The present invention also proposes a storage medium storing a computer program, which, when executed by a processor, implements a method for manufacturing spiral bevel gears based on a six-axis CNC machine tool.

[0147] In the above embodiments, the storage medium may include, but is not limited to, various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0148] Optionally, the processor executes the method steps described in the above embodiments based on the program code stored in the storage medium.

[0149] Specific examples in this embodiment can be found in the examples described in the above embodiments and optional implementations, and will not be repeated here.

[0150] Obviously, those skilled in the art should understand that the modules or steps of the present disclosure described above can be implemented using general-purpose computing devices, which can be centralized on a single computing device or distributed on a network of multiple computing devices.

[0151] Alternatively, they can be implemented using computer-executable program code, thereby allowing them to be stored in a storage device for execution by a computing device. Furthermore, in some cases, the steps shown or described can be performed in a different order than those described herein, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. Thus, this disclosure is not limited to any particular combination of hardware and software.

[0152] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A method for manufacturing spiral bevel gears based on a six-axis CNC machine tool, characterized in that, include: A three-dimensional geometric model is established based on the design parameters of the spiral bevel gear; Based on the three-dimensional geometric model, tooth surface contact analysis is performed on the spiral bevel gear to obtain tooth surface contact analysis results, including the tooth surface contact area location, contact trace distribution, and transmission error variation law. A multi-coordinate system kinematic model is established based on a six-axis CNC machine tool, wherein the multi-coordinate system includes the machine tool coordinate system, the workpiece coordinate system, and the tool coordinate system; The machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code; After machining the spiral bevel gear based on the six-axis linkage CNC machining code, tooth surface machining error information is collected. The tooth surface machining error information includes tooth surface shape error, tooth surface contact position deviation, and transmission error deviation. Based on the tooth surface machining error information and the tooth surface contact analysis results, the compensated machining parameters are obtained and fed back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, thereby achieving closed-loop optimization.

2. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 1, characterized in that, The spiral bevel gear is an arc-tooth bevel gear, and the design parameters include module, number of teeth, pitch cone angle, helix angle, tooth surface curvature parameter, and tooth width.

3. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 1, characterized in that, The spiral bevel gear is a cycloidal bevel gear, and the tooth profile of the three-dimensional geometric model is described by a cycloidal curve.

4. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 1, characterized in that, The spiral bevel gear is a quasi-hyperboloid bevel gear, and the multi-coordinate kinematic model includes workpiece axis offset parameters to adapt to transmission scenarios where workpiece axes do not intersect.

5. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 1, characterized in that, Based on the tooth surface machining error information and the tooth surface contact analysis results, compensated machining parameters are obtained and fed back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, specifically including: Based on the tooth surface contact analysis results and the type of tooth surface machining error information, the machining parameters are compensated, the compensation direction and compensation amount of the machining parameters are determined, and the compensated machining parameters are obtained. The six-axis linkage CNC machining code is updated based on the compensated machining parameters.

6. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 5, characterized in that, Compensation is applied to machining parameters, specifically including: compensating for machine tool pose parameters when the overall position of the tooth surface shifts; adjusting tool posture parameters when the shape of the tooth surface contact trace changes; and locally correcting feed parameters when there are significant local errors on the tooth surface.

7. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 1, characterized in that, The machine collects the tooth surface machining error information and collects key feature points or point cloud data of the tooth surface to calculate the machining error.

8. The method for manufacturing spiral bevel gears based on a six-axis CNC machine tool according to claim 1, characterized in that, The machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code, specifically including: The machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system through the multi-coordinate kinematic model to obtain the tool posture parameters, workpiece rotation angle parameters and feed path parameters, and generate the six-axis linkage CNC machining code.

9. A spiral bevel gear manufacturing system based on a six-axis CNC machine tool, characterized in that, include: The multi-coordinate system kinematic modeling and CNC code generation module is used to establish a three-dimensional geometric model based on the design parameters of the spiral bevel gear, and to perform tooth surface contact analysis on the spiral bevel gear based on the three-dimensional geometric model to obtain the tooth surface contact analysis results. Based on a six-axis CNC machine tool, a multi-coordinate system kinematic model is established, and the machining adjustment parameters of the spiral bevel gear are mapped to the machine tool coordinate system to generate six-axis linkage CNC machining code. The core module of the six-axis linkage machining center performs full-tooth machining of spiral bevel gears based on six-axis linkage CNC machining code; The on-machine measurement and control submodule collects tooth surface machining error information; The closed-loop optimization and parameter compensation module obtains the compensated machining parameters based on the tooth surface machining error information and tooth surface contact analysis results, and feeds them back to the CNC system of the six-axis CNC machine tool to update the six-axis linkage CNC machining code, thereby realizing closed-loop optimization.

10. A storage medium, characterized in that, The device contains a computer program that, when executed by a processor, implements the spiral bevel gear manufacturing method based on a six-axis CNC machine tool as described in any one of claims 1 to 8.

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