非圆齿轮数控滚切加工理论与自动编程系统研究
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摘要
非圆齿轮是用来实现变传动比传动的机械传动部件,和传统的变传动比机构相比,具有独特的优势。但其种类繁多,设计计算复杂,加工困难,故非圆齿轮设计制造技术自问世以来一直是制造业的热点和难点。数控技术的发展,为非圆齿轮的加工开辟了崭新途径。数控滚切加工是齿轮加工中应用最广的一种加工方法,但目前而言,非圆齿轮数控滚切加工过程中的许多理论问题尚未得到解决,故数控滚切加工方法尚未在非圆齿轮制造中发挥其应有的作用。为此,本文对非圆齿轮数控滚切加工的相关理论以及自动编程系统进行研究和探讨,主要研究内容如下：
基于滚切加工原理、直齿非圆齿轮以及斜齿非圆齿轮齿廓形成原理,分别运用工具齿条法、工具斜齿条法以及螺旋齿啮合原理,建立了直齿非圆齿轮与斜齿非圆齿轮数控滚切加工的运动模型,并以椭圆齿轮为例,通过计算机仿真验证了运动模型的正确性。
根据建立的运动模型,运用共轭曲面理论与齿廓啮合基本定理建立了数控滚切加工的直齿非圆齿轮与斜齿非圆齿轮的齿廓数学模型。
加工非圆齿轮必须采用变速比电子齿轮箱对机床运动进行控制,阐述了电子齿轮箱的原理、分类、性能要求,并将模糊自整定前馈PID控制应用于变速比电子齿轮箱的控制,仿真结果验证了其优越性。根据建立的运动模型,运用自主研制的基于锁相原理的电子齿轮功能模块与脉冲频率合成模块,设计出了直齿非圆齿轮与斜齿非圆齿轮数控滚切加工的变速比电子齿轮箱传动方案。
提出一种三次B样条曲线自适应插补算法,论述了算法的插补控制原理,并通过插补实例对该算法进行验证。插补实例表明,提出的三次B样条曲线自适应插补算法,既能保证加工精度,又能保证加工效率。最后将三次B样条曲线自适应插补算法应用于非圆齿轮数控滚切加工,并给出了具体的插补控制流程。
开发出非圆齿轮数控滚切加工参数化图形自动编程系统,系统既可以实现非圆齿轮的三维建模、运动仿真,又能实现数控滚切加工程序的自动生成。阐述了系统的组成、开发思想、系统各主要功能模块的开发过程、以及系统实现的关键如软件接口的处理、工艺库与运算库的建立等问题的解决方法。
以一对卵形齿轮为例,介绍了系统的具体运行过程。系统运行实例表明系统界面良好,运行可靠。利用自动编程系统生成的数控程序,在自主研发的数控多功能复合机床上进行验证,结果证明了自动编程系统的正确性。
Non-circular gears are used to achieve variable gear ratio transmission as mechanical transmission parts, they have many unique advantages compared with traditional institutions that are used to achieve the same aim. But because their wide range, complicated calculate and design, and difficult processing, non-circular gears design and manufacturing technology are always hot and difficult in manufacturing. However, the development of numerical control technology opens a new way of processing non-circular gears. As we know, CNC hobbing is the most widely used as a processing gears method, but now, many theoretical issues in CNC hobbing non-circular gears has not been solved, so CNC hobbing has not been play its due role for peocessing non-circular gears. Because of this, theories and automatic programming system are studied in this paper, and the main research contents are as follows:
According to principle of hobbing, spur and helical non-circular gears tooth profile forming, motion models of CNC hobbing spur and helical non-circular gears are established by using the intermediary spur tooling rack methord, the helical tooling rack metheord and helical gear meshing theory respectively. Taking oval gears as example, motion models are proved to be correct by computer simulation.
Based on motion models, mathematical models of spur and helical non-circular gears processed by hobbing are also established by using conjugate surface theory and tooth profile meshing fundamental theorem.
Variable ratio electronic gearbox must be used for motion controlling of machine tool in order to process non-circular gears. The principle, classification and performance requirements of variable ratio electronic gearbox are described, and feedforward fuzzy self-tuning PID control is used for variable ratio electronic gearbox control. After this, based on motion models, variable ratio electronic gearbox transmission schemes of hobbing spur and helical non-circular gears are designed by using electronic gear function module and pulse frequency synthesis module that have been researched independently.
A cubic B-spline curve interpolation algorithm is proposed, and the algorithm of interpolation control theory is discussed. The interpolation algorithm is verified by an example, and the result shows that this algorithm can not only guarantee processing precision but also can ensure processing efficiency. Then, this interpolation algorithm is applied to CNC hobbing non-circular gears, and specific interpolation control process is provided.
A parametric and graphical automatic programming system for hobbing non-circular gears is developed. This system can be achieved non-circular gears3D modeling, motion simulation and programs of CNC hobbing automatic generation. The components, development ideas of system are described, the development process of the major functional modules in this system, how to settle the key problem such as software interfaces processing, and how to establish computing and technology libraries are also discussed in this article.
Lastly, the specific running process is introduced by taking a pair of oval gears as example. The result shows that the system has good interface and reliable operation. Then, using the NC program geberated by the automatic programming system, a pair of non-circular gears is processed using multi-functional complex CNC machine tool which has been self-developed, and this system is proved to be correct by the result of processing.
基于滚切加工原理、直齿非圆齿轮以及斜齿非圆齿轮齿廓形成原理,分别运用工具齿条法、工具斜齿条法以及螺旋齿啮合原理,建立了直齿非圆齿轮与斜齿非圆齿轮数控滚切加工的运动模型,并以椭圆齿轮为例,通过计算机仿真验证了运动模型的正确性。
根据建立的运动模型,运用共轭曲面理论与齿廓啮合基本定理建立了数控滚切加工的直齿非圆齿轮与斜齿非圆齿轮的齿廓数学模型。
加工非圆齿轮必须采用变速比电子齿轮箱对机床运动进行控制,阐述了电子齿轮箱的原理、分类、性能要求,并将模糊自整定前馈PID控制应用于变速比电子齿轮箱的控制,仿真结果验证了其优越性。根据建立的运动模型,运用自主研制的基于锁相原理的电子齿轮功能模块与脉冲频率合成模块,设计出了直齿非圆齿轮与斜齿非圆齿轮数控滚切加工的变速比电子齿轮箱传动方案。
提出一种三次B样条曲线自适应插补算法,论述了算法的插补控制原理,并通过插补实例对该算法进行验证。插补实例表明,提出的三次B样条曲线自适应插补算法,既能保证加工精度,又能保证加工效率。最后将三次B样条曲线自适应插补算法应用于非圆齿轮数控滚切加工,并给出了具体的插补控制流程。
开发出非圆齿轮数控滚切加工参数化图形自动编程系统,系统既可以实现非圆齿轮的三维建模、运动仿真,又能实现数控滚切加工程序的自动生成。阐述了系统的组成、开发思想、系统各主要功能模块的开发过程、以及系统实现的关键如软件接口的处理、工艺库与运算库的建立等问题的解决方法。
以一对卵形齿轮为例,介绍了系统的具体运行过程。系统运行实例表明系统界面良好,运行可靠。利用自动编程系统生成的数控程序,在自主研发的数控多功能复合机床上进行验证,结果证明了自动编程系统的正确性。
Non-circular gears are used to achieve variable gear ratio transmission as mechanical transmission parts, they have many unique advantages compared with traditional institutions that are used to achieve the same aim. But because their wide range, complicated calculate and design, and difficult processing, non-circular gears design and manufacturing technology are always hot and difficult in manufacturing. However, the development of numerical control technology opens a new way of processing non-circular gears. As we know, CNC hobbing is the most widely used as a processing gears method, but now, many theoretical issues in CNC hobbing non-circular gears has not been solved, so CNC hobbing has not been play its due role for peocessing non-circular gears. Because of this, theories and automatic programming system are studied in this paper, and the main research contents are as follows:
According to principle of hobbing, spur and helical non-circular gears tooth profile forming, motion models of CNC hobbing spur and helical non-circular gears are established by using the intermediary spur tooling rack methord, the helical tooling rack metheord and helical gear meshing theory respectively. Taking oval gears as example, motion models are proved to be correct by computer simulation.
Based on motion models, mathematical models of spur and helical non-circular gears processed by hobbing are also established by using conjugate surface theory and tooth profile meshing fundamental theorem.
Variable ratio electronic gearbox must be used for motion controlling of machine tool in order to process non-circular gears. The principle, classification and performance requirements of variable ratio electronic gearbox are described, and feedforward fuzzy self-tuning PID control is used for variable ratio electronic gearbox control. After this, based on motion models, variable ratio electronic gearbox transmission schemes of hobbing spur and helical non-circular gears are designed by using electronic gear function module and pulse frequency synthesis module that have been researched independently.
A cubic B-spline curve interpolation algorithm is proposed, and the algorithm of interpolation control theory is discussed. The interpolation algorithm is verified by an example, and the result shows that this algorithm can not only guarantee processing precision but also can ensure processing efficiency. Then, this interpolation algorithm is applied to CNC hobbing non-circular gears, and specific interpolation control process is provided.
A parametric and graphical automatic programming system for hobbing non-circular gears is developed. This system can be achieved non-circular gears3D modeling, motion simulation and programs of CNC hobbing automatic generation. The components, development ideas of system are described, the development process of the major functional modules in this system, how to settle the key problem such as software interfaces processing, and how to establish computing and technology libraries are also discussed in this article.
Lastly, the specific running process is introduced by taking a pair of oval gears as example. The result shows that the system has good interface and reliable operation. Then, using the NC program geberated by the automatic programming system, a pair of non-circular gears is processed using multi-functional complex CNC machine tool which has been self-developed, and this system is proved to be correct by the result of processing.
引文
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