Bevel gear cutting tool using three-axis machining center

Abstract

This utility model discloses a tooling for cutting bevel gears using a three-axis machining center, belonging to the field of bevel gear machining technology. It includes a machine tool table of the three-axis machining center, a tooling base plate mounted on the machine tool table via a bolt (a) through a T-slot, a tooling back plate inclinedly mounted on the tooling base plate, a manually rotating indexing disc mounted on the tooling back plate via a bolt (b), a workpiece mandrel mounted on the manually rotating indexing disc via a bolt (c) through a T-slot, and a workpiece bevel gear mounted on the workpiece mandrel via a connecting key, bolts, and a pressure plate. This utility model has strong environmental adaptability, is economical and practical, has a simple structure, is easy to operate, and has good stability. It reduces labor costs while simultaneously lowering the scrap rate and shortening processing time due to higher machining accuracy and efficiency, significantly improving output and efficiency, and significantly enhancing product consistency, thus creating certain economic benefits.

Description

Technical Field

[0001] This utility model relates to the field of bevel gear processing technology, specifically to a tool for cutting bevel gears using a three-axis machining center. Background Technology

[0002] Bevel gears are typically used to transmit vertical motion between two shafts and have specific angles, such as the common 30° and 45°. Their tooth profile is distributed along a conical surface, and their geometric parameters include the number of teeth, module, pressure angle, pitch cone angle, and root cone angle, making them more complex to manufacture than spur or helical gears. Traditional machining methods may include gear hobbing, gear shaping, or form milling, but these may require specialized machine tools. Due to limited machining conditions in our company's workshop, we lack dedicated machine tools for processing bevel gears. Therefore, we need to consider the possibility of using a three-axis machining center, i.e., a CNC machine tool, which has three linear motion axes (X, Y, Z), to machine bevel gears. While three-axis machine tools are flexible, they lack dedicated rotary axes, so programming and tooling fixtures may be necessary to achieve bevel gear machining. Therefore, we require utilizing existing three-axis machining centers and tooling fixtures to cut the tooth profile of bevel gears without dedicated machine tools, reducing labor and material costs and lowering operating costs. Utility Model Content

[0003] The purpose of this invention is to provide a tool for cutting bevel gears using a three-axis machining center, in order to solve the problems existing in the prior art.

[0004] The technical solution adopted in this utility model is as follows:

[0005] A tooling for cutting bevel gears using a three-axis machining center includes a machine tool table 1 of the three-axis machining center. A tooling base plate 2 is mounted on the machine tool table 1 via a bolt a3 through a T-slot. A tooling back plate 7 is inclinedly mounted on the tooling base plate 2. A manually rotating indexing disc 9 is mounted on the tooling back plate 7 via a bolt b8. A workpiece mandrel 11 is mounted on the manually rotating indexing disc 9 via a bolt c10 through a T-slot. A workpiece bevel gear 12 is mounted on the workpiece mandrel 11 via a connecting key 13, a bolt d14, and a pressure plate 15.

[0006] Two tooling support ribs 4 are welded between the back of the tooling base plate 2 and the tooling back plate 7.

[0007] The base plate 2 of the fixture is a steel plate with a thickness of 25mm; the supporting rib plate 4 of the fixture is a steel plate with a thickness of 30mm; and the back plate 7 of the fixture is a steel plate with a thickness of 30mm.

[0008] The pressure plate 15 is fixed to the end face of the workpiece mandrel 11 by bolts d14, and the edge of the pressure plate 15 presses against the workpiece bevel gear 12.

[0009] The three-axis machining center has a T-slot machined on its table 1 for mounting T-slot bolts a3, and the fixture base plate 2 has U-slots machined on its front and rear sides for mounting T-slot bolts a3.

[0010] The manual rotating indexing disc 9 has a countersunk hole in the center, and a tension bolt 5 is installed in the countersunk hole. The tension bolt 5 passes through the tool back plate 7 and is fixed by a nut. A round washer 6 is provided between the nut and the tool back plate 7.

[0011] The manual rotating indexing disc 9 has several T-slots machined on its end face for mounting T-slot bolts c10. The workpiece mandrel 11 has holes drilled on its bottom face, and T-slot bolts c10 are inserted into the holes. The T-slot bolts c10 are then engaged in the T-slots on the end face of the manual rotating indexing disc 9.

[0012] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0013] 1. This utility model utilizes a three-axis machining center and clamping fixtures to cut bevel gears, breaking through the traditional bevel gear machining method. It employs a three-axis linkage combined with specific processes and clamping fixtures to achieve the cutting of the bevel gear tooth profile. During cutting, roughing and finishing can be completed in a single operation, reducing the number of workpiece loading and unloading operations. Compared to traditional machining methods, the processing time is shorter, the work schedule is more compact, significantly reducing the labor intensity of workers, greatly improving work efficiency, and increasing the pass rate.

[0014] 2. This utility model has a simple structure, strong adaptability, high safety, and low cost. It achieves the goal of reducing labor and improving work efficiency.

[0015] 4. Since this utility model was put into use, it has been very practical, reducing the labor intensity of operators, greatly improving work efficiency, significantly reducing the cutting process and time, making it more compact, and ensuring the accuracy of bevel gear tooth profile and other indicators.

[0016] 5. The application of this utility model has saved the company approximately 250,000 yuan in costs by purchasing a dedicated bevel gear cutting machine tool; secondly, it has reduced the cost of cutting tools and auxiliary materials, reduced cutting time, and improved work efficiency, resulting in an overall cost reduction of more than 60,000 yuan.

[0017] In summary, this utility model boasts strong environmental adaptability, economic practicality, simple structure, easy operation, strong site adaptability, high stability, reduced labor costs, ease of inspection and maintenance, and a design without blind spots. Simultaneously, its high processing accuracy and efficiency reduce scrap rates and processing time, significantly improving output and efficiency, and substantially enhancing product consistency, thus generating substantial economic benefits. It enables faster workpiece processing, increases processing speed, reduces scrap rates, enhances processing efficiency, improves the accuracy and surface quality of processed parts, lowers costs, and demonstrates the advantages of flexible manufacturing. Furthermore, this utility model aligns with the technological development trend of intelligent and high-precision machining, contributing to the widespread adoption of three-axis machining centers. Against the backdrop of accelerated domestic substitution and gradually decreasing costs, it provides small and medium-sized enterprises with a more attractive, cost-effective solution. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of this utility model;

[0019] Figure 2 This is a front view of the manually rotating indexing disk of this utility model;

[0020] Figure 3 This is a top view of the manually rotating indexing disc of this utility model;

[0021] Figure 4 This is a schematic diagram of the structure of the workpiece mandrel of this utility model;

[0022] Figure 5 This is a schematic diagram of the bevel gear structure of the workpiece in this utility model;

[0023] In the diagram: 1. Machine tool table of a three-axis machining center; 2. Fixture base plate; 3. Bolt a; 4. Fixture support rib; 5. Tensioning bolt; 6. Round pad; 7. Fixture back plate; 8. Bolt b; 9. Manually rotated indexing disc; 10. T-slot bolt c; 11. Workpiece mandrel; 12. Workpiece bevel gear; 13. Connecting key; 14. Bolt d; 15. Pressure plate; 16. Machining tool. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0025] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0026] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0027] Example 1

[0028] like Figure 1-5 As shown, this embodiment provides a tooling for cutting bevel gears using a three-axis machining center. The tooling includes a machine table 1, on which a tooling base plate 2 is mounted via bolts a3 and T-slots. A tooling back plate 7 is inclinedly mounted on the base plate 2. A manually rotating indexing disc 9 is mounted on the back plate 7 via bolts b8. A workpiece mandrel 11 is mounted on the manually rotating indexing disc 9 via bolts c10 and T-slots. A hole is drilled in the workpiece mandrel 11, and the T-slot bolts c10 are inserted into the T-slots on the end face of the manually rotating indexing disc 9, thus fixing the mandrel on the rotating disc. A workpiece bevel gear 12 is mounted on the workpiece mandrel 11 via a connecting key 13, bolts d14, and a 10mm thick pressure plate 15.

[0029] Two tooling support ribs 4 are welded between the back of the tooling base plate 2 and the tooling back plate 7.

[0030] The base plate 2 of the fixture is a steel plate with a thickness of 25mm; the supporting rib plate 4 of the fixture is a steel plate with a thickness of 30mm; and the back plate 7 of the fixture is a steel plate with a thickness of 30mm.

[0031] The pressure plate 15 is fixed to the end face of the workpiece mandrel 11 by bolts d14, and the edge of the pressure plate 15 presses against the workpiece bevel gear 12.

[0032] The three-axis machining center has a T-slot machined on its table 1 for mounting T-slot bolts a3, and the fixture base plate 2 has U-slots machined on its front and rear sides for mounting T-slot bolts a3.

[0033] The manual rotating indexing disc 9 has a countersunk hole in the center, and a tension bolt 5 is installed in the countersunk hole. The tension bolt 5 passes through the tool back plate 7 and is fixed by a nut. A round washer 6 is provided between the nut and the tool back plate 7.

[0034] The manual rotating indexing disc 9 has three T-slots machined on its end face for mounting T-slot bolts c10. The workpiece mandrel 11 has holes drilled on its bottom face, and T-slot bolts c10 are inserted into the holes. The T-slot bolts c10 are then engaged in the T-slots on the end face of the manual rotating indexing disc 9.

[0035] The manufacturing process of this utility model is as follows: A 600x600x25mm steel plate is selected as the base plate of the fixture. U-shaped grooves are machined on both sides of the base plate. A 600x600x30mm steel plate is selected as the back plate of the fixture. The back plate is welded to the base plate according to the position of the main view of the bevel gear cutting fixture, and tilted at a certain angle, the tilt angle corresponding to the cone angle of the bevel gear tooth profile. To prevent the back plate from being not firmly welded, two 30mm thick fixture support ribs are welded between the base plate and the back plate to provide support. This completes the assembly of the fixture base. Because there is a T-slot on the table of the three-axis machining center, the fixture base is fixed to the machine table using bolts a3, nuts, and washers M20mm.

[0036] Next, select a suitable manually rotating indexing disc. Since the disc has two U-shaped grooves on its bottom and a through hole in its center, drill holes at the corresponding positions on the back plate after measuring the dimensions. Secure the disc to the back plate on both sides using M12 bolts (b8), nuts, and washers. Further tighten and fix the indexing disc to the back plate at the center using M24mm tension bolts (5), nuts, washers, and a 12mm thick round washer. When machining bevel gear teeth, the manually rotating indexing disc can accurately and evenly divide the spur gear teeth.

[0037] Select the material to process the workpiece mandrel. Drill holes on the bottom surface of the workpiece mandrel according to the view and process the keyway on the shaft. Since the indexing disc has a formed T-slot, the workpiece mandrel can be fixed on the indexing disc surface with M12mm T-slot bolts, C10 nuts and washers. The workpiece mandrel can then rotate with the disc.

[0038] The workpiece blank is mounted on the workpiece mandrel and keyed. A hole is drilled in the center of the mandrel end face to form a threaded connection. A δ10mm pressure plate is then pressed onto the workpiece mandrel end face using a d14 bolt and an M12mm bolt washer to prevent the bevel gear blank from moving during machining. When the rotating disc is manually cranked, the bevel gear will rotate accordingly.

[0039] Machining bevel gears requires the use of form milling cutters or dedicated high-speed steel cutting tools. For hard materials, coated inserts or CBN tools are needed to improve efficiency and surface quality. The radius of the cutting tool should be smaller than the minimum width of the tooth groove. First, use a form milling cutter for rough machining of a single tooth, then use an end mill for finishing. Adjust the milling cutter's cutting edge angle according to the bevel gear's helix angle to reduce interference. For rough machining of bevel gears, use a disc milling cutter (diameter φ60~φ100mm), and for finishing, use a finger milling cutter (4~6 teeth) to improve tooth profile accuracy.

[0040] In the application of this invention, a three-axis machining center (CNC machine tool) is used to program the cutting path for the bevel gear. Since the bevel gear's tooth profile is a gradually tapering cone, helical interpolation or equidistant lines are needed to generate the cutting path. This requires CAM software to program the toolpath. Considering the influence of the taper, the position and depth of each cutting line need to be calculated based on the taper. Furthermore, the strategies for roughing and finishing differ; roughing may require a larger cutting depth, while finishing requires a smaller step size and higher precision. This invention utilizes the precise angle division feature of a manually rotated indexing disc. By rotating the spindle, the scale dial rotates, clamping the workpiece in a chuck or between two centers, achieving precise measurement, indexing, and positioning of the workpiece, accurately dividing the number of teeth on the bevel gear. In this invention, since the axis of the bevel gear may be inclined, the workpiece needs to be fixed in an appropriate position to ensure accurate positioning during machining. A tilting device matching the workpiece angle needs to be designed to align it with the machine tool's coordinate system, ensuring precise cutting of the tooth profile by the machine tool. Additionally, the tilting device should also prevent vibration and deformation during machining. Finally, the choice of cutting tools is also crucial. Machining bevel gears requires form milling cutters or specialized high-speed steel tools. For hard materials, coated inserts or CBN tools are needed to improve efficiency and surface quality. The tool radius should be smaller than the minimum width of the tooth groove to avoid interference. This reduces labor and material costs, lowering operating costs.

Claims

1. A bevel gear cutting tool using a three-axis machining center comprising a three-axis machining center machine table (1), characterized in that, The table (1) of the three-axis machining center is provided with a fixture base plate (2) by bolt a (3) through a T-slot. The fixture base plate (2) is provided with a fixture back plate (7) at an inclination. The fixture back plate (7) is provided with a manual rotating indexing disc (9) by bolt b (8). The manual rotating indexing disc (9) is provided with a workpiece mandrel (11) by bolt c (10) through a T-slot. The workpiece mandrel (11) is provided with a workpiece bevel gear (12) by connecting key (13), bolt d (14) and pressure plate (15).

2. A method of cutting bevel gears using a three-axis machining center according to claim 1, wherein: Two tooling support ribs (4) are welded between the back of the tooling base plate (2) and the tooling back plate (7).

3. A method of cutting bevel gears with a three-axis machining center according to claim 2, characterized in that: The base plate (2) of the fixture is a steel plate with a thickness of 25mm; the supporting rib plate (4) of the fixture is a steel plate with a thickness of 30mm; the back plate (7) of the fixture is a steel plate with a thickness of 30mm.

4. The bevel gear cutting tool using a three-axis machining center according to claim 1, wherein: The pressure plate (15) is fixed to the end face of the workpiece mandrel (11) by bolt d (14), and the edge of the pressure plate (15) presses on the workpiece bevel gear (12).

5. A method of cutting bevel gears using a three-axis machining center according to claim 1, wherein: The three-axis machining center has a T-slot machined on the table (1) for mounting T-slot bolts a (3), and the fixture base plate (2) has U-slots machined on the front and rear sides for mounting T-slot bolts a (3).

6. A method of cutting bevel gears using a three-axis machining center according to claim 1, wherein: The manual rotating indexing disc (9) has a countersunk hole in the center, and a tension bolt (5) is installed in the countersunk hole. The tension bolt (5) passes through the tool back plate (7) and is fixed by a nut. A round washer (6) is installed between the nut and the tool back plate (7).

7. A method of cutting bevel gears using a three-axis machining center according to claim 1, wherein: The manual rotating indexing disc (9) has several T-slots machined on its end face for installing T-slot bolts c (10). The workpiece mandrel (11) has holes drilled on its bottom face, and T-slot bolts c (10) are inserted into the holes. The T-slot bolts c (10) are then inserted into the T-slots on the end face of the manual rotating indexing disc (9).

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