螺旋锥齿轮五轴联动数控加工的研究
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摘要
螺旋锥齿轮是实现相交轴运动传递的基础元件，由于其传动具有重合度大、承载能力高、传动效率高、传动平稳、噪声小等优点而被广泛应用于汽车、飞机、机床和各种机械产品中。由于其原理上的复杂性，导致机床结构和加工调整在所有金属切削机床中最为复杂且加工周期长。因此，研究高速、高精、高效和柔性自动化的螺旋锥齿轮加工机床显得尤为重要。
随着计算机技术和数字控制技术的发展、高精度电子传动的实现，为高精、高效和柔性化的齿轮加工开辟了新的途径。目前国外齿轮厂家纷纷采用先进的五轴联动数控加工方法来加工螺旋锥齿轮以提高其加工精度。五坐标轴联动数控加工广泛应用于模具、涡轮叶片、船用螺旋桨和航空部件等复杂零件的加工。由于同传统三坐标加工相比增加了两个附加的自由度，五坐标加工能够获得更高的生产效率和更好的加工质量，尤其在加工复杂的空间曲面时比传统的数控具有更高的加工精度。
目前国内加工螺旋锥齿轮的机床主要是传统机床，数控化的机床主要依靠进口，不但价格非常昂贵，而且技术上受制于人。尽管国内生产数控螺旋锥齿轮机床的厂商已有几家，但是他们的数控系统仍以引进国外FANUC、Siemens和Philips公司为主，由于锥齿轮加工自身的特点，这些通用的数控系统不能充分发挥其性能，CAD与CAM未能实现一体化，价格也较贵。如果依靠进口，机床价格更贵，并且国外公司也实现技术封锁，这对于我国齿轮机床的应用极为不利。因此，根据锥齿轮加工特点需要有自己的一套数控系统，利用我所在数控方面的成功开发经验，我们便提出了开发螺旋锥齿轮五坐标轴联动数控加工系统的构想。作者承担了此任务，本课题来源于河南省自然科学基金项目“仿形数字化加工技术研究”，项目编号：004053100。
围绕该课题本文主要进行了以下几个方面的研究工作：
1．对五轴联动数控机床进行简要的分析，主要包括机床的结构形式、配置种类、坐标变换方法及刀轴控制方式等，这对螺旋锥齿轮五轴联动数控加工的设计具有重要的理论和实际意义。
2．对螺旋锥齿轮的啮合原理进行了介绍，主要包括相对微分法、啮合方程、第二共轭曲面的确定方法、诱导法曲率及点接触共轭曲面等，通过基本参数的输入，对螺旋锥齿轮的大小齿面进行计算，求解出齿面坐标，建立了螺旋锥齿轮齿面模型。
3．根据齿面计算所得到的结果，进行螺旋锥齿轮五轴联动数控加工前置处理，计算出螺旋锥齿轮五轴联动数控加工刀位轨迹。
4．基于五坐标数控加工后置处理原理，根据建立的机床模型，求解出了螺旋锥齿轮数控机床的后置处理算法，编制锥齿轮后置处理器，并利用该处理器生成螺旋锥齿轮五轴联动数控加工程序，该程序输入数控机床即可加工出螺旋锥齿轮。
摘要
5.利用VC一集成环境编程，求解齿面模型三维数据、得到螺旋锥齿轮五轴联动数
控加工的刀位文件和后置处理程序。
本课题将先进的五轴联动数控技术和螺旋锥齿轮加工技术相结合，用计算机技术改进
传统的螺旋锥齿轮加工技术，发挥本所在数控系统软硬件方面的优势，结合国内外的先进
成果，尝试开发具有自主产权的螺旋锥齿轮五轴联动数控加工系统，为打破国外垄断，赶
超国外水平，发展我国锥齿轮制造的数控产业化做出贡献。由于本课题的研究领域新颖，
机电结合涉及面广，因此需要扎实的数学理论知识和较广的专业知识。由于螺旋锥齿轮的
五轴联动数控加工的研究几乎涉及到了整个制造环节，因此要实际加工出螺旋锥齿轮，在
本课题的基础上，还需在以下几个方面作进一步深入的研究:
1.螺旋锥齿轮五轴联动加工仿真的研究，通过研究加工仿真来优化整个加工过程。
2.五轴联动数控加工实时插补算法的研究和控制软件的编制。
3.锥齿轮实际加工工艺流程的合理安排和优化。
Spiral bevel gears are one of basic mechanical units that transmit motion between concurrent axes. Thanks to the great merits of the transmission, such as the big overlap ratio, the high loading capacity, the high transmitting efficiency, the stability, the small noises, and so on, they are widely used in automotive vehicle, planes, machine tools and all kinds of machines. However, the theoretical complexity causes that the machine tool structure and the machining adjustment are the most complex among all the stock-removing machines, and that the machining periodicity is very long. Therefore, it is of much importance to study machine tools of spiral bevel gears with high speed, high precision, high efficiency, much flexibility and high automation.
The development of the computer and NC technology and the realization of the high precision electronic transmission enable machining gears with high precision, high efficiency, and much flexibility. Now, one after another, foreign gear plants adopt the advanced five-axes coordinated numerical controlling machining technique to machine spiral bevels in order to improve machining precision. Five-axes coordinated numerical controlling machining technique is applied widely in machining such complex parts as mould, laminae of turbine, screw propeller and avigation parts etc. Compared with traditional three-axes coordinated numerical controlling machining technique, five-axes coordinated numerical controlling machining technique increases two odditional freedoms so it can obtain higher machining efficiency and precision, especially in machining complex curved surfaces.
Now national NC machines using in machining spiral bevel gears are mainly traditional machines and the NC machines depend on importation,not only the price being high,but being locked. Although there have been several domestic manufacturers producing NC macinges using in macining spiral beval gears, their NC system still mainly depends on introduction from foreign companies such as FANUC,Siemens and Philips, this universal CNC system is unable to make full of its functions, and CAD and CAM are independent. What's more, the price is also very high. If we only rely on importation, the higher price of tools and the blocked technology are very disadvantageous to the application of gear machines in our countries. So we should have our own CNC systems of spiral bevel gears. In view of our successfully-developing experience for many years, we put forward the thought of developing the CNC system for spiral bevel gears. My dissertation has drawn from the project - the Study of Copying & Digitizing Machining Technolog
y which is sponsored by Natural Science Foundation of Henan province(Item number: 004053100).
Centered around this subject, this paper mainly studies as follows:
1. Briefly analyzes the five-axes coordinated numerical controlling machine tools, mainly including structure form, scheme variety, coordinate switching technique and cutter shaft controlling manner etc which is very important to the design of five-axes coordinated numerical controlling machining technology of spiral bevel gears.
2. The engagement theory of spiral bevel gears is presented, mainly including the tangent plane, normal vector, curvature of spatial curved surfaces and relative curvature of conjugate surfaces, et al, according to the inputting of basic parameters, calculating the tooth flank of the spiral bevel gears, solving out the coordinates of tooth flanks, establishing the tooth flank models of spiral bevel gears.
3. According to the result of flank of tooth calculating ,pre-proccess the spiral bevel gears and figure out the cutter location of spiral bevel gears NC maching
4. Based on post-proccessing principle of five-axes coordinated numerical controlling machining and according to the established mathematical model of machine tools, deduces out post-processing algorithm of CNC machine tools for spiral bevel gears, program the post-proccessing tool for spiral bevel gears and uses the tool to pr
随着计算机技术和数字控制技术的发展、高精度电子传动的实现，为高精、高效和柔性化的齿轮加工开辟了新的途径。目前国外齿轮厂家纷纷采用先进的五轴联动数控加工方法来加工螺旋锥齿轮以提高其加工精度。五坐标轴联动数控加工广泛应用于模具、涡轮叶片、船用螺旋桨和航空部件等复杂零件的加工。由于同传统三坐标加工相比增加了两个附加的自由度，五坐标加工能够获得更高的生产效率和更好的加工质量，尤其在加工复杂的空间曲面时比传统的数控具有更高的加工精度。
目前国内加工螺旋锥齿轮的机床主要是传统机床，数控化的机床主要依靠进口，不但价格非常昂贵，而且技术上受制于人。尽管国内生产数控螺旋锥齿轮机床的厂商已有几家，但是他们的数控系统仍以引进国外FANUC、Siemens和Philips公司为主，由于锥齿轮加工自身的特点，这些通用的数控系统不能充分发挥其性能，CAD与CAM未能实现一体化，价格也较贵。如果依靠进口，机床价格更贵，并且国外公司也实现技术封锁，这对于我国齿轮机床的应用极为不利。因此，根据锥齿轮加工特点需要有自己的一套数控系统，利用我所在数控方面的成功开发经验，我们便提出了开发螺旋锥齿轮五坐标轴联动数控加工系统的构想。作者承担了此任务，本课题来源于河南省自然科学基金项目“仿形数字化加工技术研究”，项目编号：004053100。
围绕该课题本文主要进行了以下几个方面的研究工作：
1．对五轴联动数控机床进行简要的分析，主要包括机床的结构形式、配置种类、坐标变换方法及刀轴控制方式等，这对螺旋锥齿轮五轴联动数控加工的设计具有重要的理论和实际意义。
2．对螺旋锥齿轮的啮合原理进行了介绍，主要包括相对微分法、啮合方程、第二共轭曲面的确定方法、诱导法曲率及点接触共轭曲面等，通过基本参数的输入，对螺旋锥齿轮的大小齿面进行计算，求解出齿面坐标，建立了螺旋锥齿轮齿面模型。
3．根据齿面计算所得到的结果，进行螺旋锥齿轮五轴联动数控加工前置处理，计算出螺旋锥齿轮五轴联动数控加工刀位轨迹。
4．基于五坐标数控加工后置处理原理，根据建立的机床模型，求解出了螺旋锥齿轮数控机床的后置处理算法，编制锥齿轮后置处理器，并利用该处理器生成螺旋锥齿轮五轴联动数控加工程序，该程序输入数控机床即可加工出螺旋锥齿轮。
摘要
5.利用VC一集成环境编程，求解齿面模型三维数据、得到螺旋锥齿轮五轴联动数
控加工的刀位文件和后置处理程序。
本课题将先进的五轴联动数控技术和螺旋锥齿轮加工技术相结合，用计算机技术改进
传统的螺旋锥齿轮加工技术，发挥本所在数控系统软硬件方面的优势，结合国内外的先进
成果，尝试开发具有自主产权的螺旋锥齿轮五轴联动数控加工系统，为打破国外垄断，赶
超国外水平，发展我国锥齿轮制造的数控产业化做出贡献。由于本课题的研究领域新颖，
机电结合涉及面广，因此需要扎实的数学理论知识和较广的专业知识。由于螺旋锥齿轮的
五轴联动数控加工的研究几乎涉及到了整个制造环节，因此要实际加工出螺旋锥齿轮，在
本课题的基础上，还需在以下几个方面作进一步深入的研究:
1.螺旋锥齿轮五轴联动加工仿真的研究，通过研究加工仿真来优化整个加工过程。
2.五轴联动数控加工实时插补算法的研究和控制软件的编制。
3.锥齿轮实际加工工艺流程的合理安排和优化。
Spiral bevel gears are one of basic mechanical units that transmit motion between concurrent axes. Thanks to the great merits of the transmission, such as the big overlap ratio, the high loading capacity, the high transmitting efficiency, the stability, the small noises, and so on, they are widely used in automotive vehicle, planes, machine tools and all kinds of machines. However, the theoretical complexity causes that the machine tool structure and the machining adjustment are the most complex among all the stock-removing machines, and that the machining periodicity is very long. Therefore, it is of much importance to study machine tools of spiral bevel gears with high speed, high precision, high efficiency, much flexibility and high automation.
The development of the computer and NC technology and the realization of the high precision electronic transmission enable machining gears with high precision, high efficiency, and much flexibility. Now, one after another, foreign gear plants adopt the advanced five-axes coordinated numerical controlling machining technique to machine spiral bevels in order to improve machining precision. Five-axes coordinated numerical controlling machining technique is applied widely in machining such complex parts as mould, laminae of turbine, screw propeller and avigation parts etc. Compared with traditional three-axes coordinated numerical controlling machining technique, five-axes coordinated numerical controlling machining technique increases two odditional freedoms so it can obtain higher machining efficiency and precision, especially in machining complex curved surfaces.
Now national NC machines using in machining spiral bevel gears are mainly traditional machines and the NC machines depend on importation,not only the price being high,but being locked. Although there have been several domestic manufacturers producing NC macinges using in macining spiral beval gears, their NC system still mainly depends on introduction from foreign companies such as FANUC,Siemens and Philips, this universal CNC system is unable to make full of its functions, and CAD and CAM are independent. What's more, the price is also very high. If we only rely on importation, the higher price of tools and the blocked technology are very disadvantageous to the application of gear machines in our countries. So we should have our own CNC systems of spiral bevel gears. In view of our successfully-developing experience for many years, we put forward the thought of developing the CNC system for spiral bevel gears. My dissertation has drawn from the project - the Study of Copying & Digitizing Machining Technolog
y which is sponsored by Natural Science Foundation of Henan province(Item number: 004053100).
Centered around this subject, this paper mainly studies as follows:
1. Briefly analyzes the five-axes coordinated numerical controlling machine tools, mainly including structure form, scheme variety, coordinate switching technique and cutter shaft controlling manner etc which is very important to the design of five-axes coordinated numerical controlling machining technology of spiral bevel gears.
2. The engagement theory of spiral bevel gears is presented, mainly including the tangent plane, normal vector, curvature of spatial curved surfaces and relative curvature of conjugate surfaces, et al, according to the inputting of basic parameters, calculating the tooth flank of the spiral bevel gears, solving out the coordinates of tooth flanks, establishing the tooth flank models of spiral bevel gears.
3. According to the result of flank of tooth calculating ,pre-proccess the spiral bevel gears and figure out the cutter location of spiral bevel gears NC maching
4. Based on post-proccessing principle of five-axes coordinated numerical controlling machining and according to the established mathematical model of machine tools, deduces out post-processing algorithm of CNC machine tools for spiral bevel gears, program the post-proccessing tool for spiral bevel gears and uses the tool to pr
引文
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