摆线齿锥齿轮数控加工装备及其数字化制造关键技术的研究
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摘要
摆线齿锥齿轮是大型、重型机械设备中传递相交轴运动和动力的关键零件。目前,摆线齿锥齿轮的数控加工装备及其数字化制造技术仍为德国Klingelnberg公司所拥有,而我国在该领域的研究尚处于起步阶段。为了提高我国摆线齿锥齿轮数控加工装备的自主创新能力以及摆线齿锥齿轮的数字化制造水平,本文对摆线齿锥齿轮的数控加工装备及其数字化制造关键技术进行了研究,主要研究成果如下：
1、基于螺旋锥齿轮传动的啮合理论,对现有摆线齿锥齿轮切齿算法的不足之处进行了改进。通过设定相啮合齿面在参考点处接触椭圆的长轴长度,根据齿面参考点的曲率参数,运用迭代算法确定了外刀盘修正齿长曲率时的偏距EXB。通过控制外刀盘回转中心的偏距EXF保证了轮齿的齿厚,避免了现有算法产生的螺旋角偏差和曲率偏差。基于KN3028、KN3030标准和改进后的切齿算法,开发了计算机辅助设计软件,并通过实例对软件的计算结果进行了验证。
2、基于齿轮啮合理论,建立了摆线齿锥齿轮的齿面方程以及齿面曲率参数的计算方法。根据大、小轮的齿面方程及齿面的曲率参数,建立了摆线齿锥齿轮齿面接触分析的方法,不仅可以分析齿轮副在理论安装位置时的接触情况,还可以得到齿轮副在齿面大端、中点、小端啮合时的接触区、传动误差曲线以及V、H调整量。通过实际的切齿加工实验,验证了切齿算法和齿面接触分析方法的正确性。
3、基于摆线齿锥齿轮的齿面方程,给出了齿面各离散点在机床调整位置以及在展成加工位置时的径矢和法矢的计算公式,并提出了一种精确计算展成起始和展成终止摇台角的算法。此外,建立了一种齿形分析的方法,并分析了各种机床调整参数对齿形的影响规律及影响程度。在此基础上,建立了一种修正齿形误差的方法,根据测量数据,可得到修正切齿加工误差或补偿热处理变形的机床调整参数修正量。
4、基于摆线齿锥齿轮的数控加工原理,提出了一种新的刀具主轴结构,可实现外刀盘轴线偏距的调整以及外刀盘轴线偏置方向角的连续调整。基于数控机床与机械式机床运动变换的原理以及H1600K型数控机床的数控加工坐标系,建立了摆线齿锥齿轮数控加工的数学模型。利用该数学模型以及数控系统的“电子齿轮”功能,可生成数控加工的程序代码,进而实现摆线齿锥齿轮的数控加工。
5、基于H1600K型数控摆线齿锥齿轮铣齿机,提出了在机测量系统的结构。针对CMM和齿轮测量中心测量小轮时存在的问题,提出了基于展成原理的齿形误差在机测量方法,可利用小直径测球的直测针无干涉地完成齿面的测量。给出了齿形误差和齿轮分度精度的在机测量过程以及测量数据的处理方法。基于AutoCAD的二次开发功能,开发了仿真软件,通过对比仿真测量结果和理论分析结果,验证了在机测量原理的正确性。
Cyclo-Palloid spiral bevel gears are the key components of the large or heavy mechanical equipment for transmitting motion and power between intersecting axes. At present, CNC machining equipment and digital manufacturing technologies of Cyclo-Palloid spiral bevel gears are still owned by Klingelnberg Corporation in Germany. But in the field of CNC machining equipment and manufacturing technologies, the domestic companies are still in the initial stage. In order to improve the independent innovation capacity of CNC machining equipment and enhance the digital manufacturing level of Cyclo-Palloid spiral bevel gears, the CNC machining equipment and key technologies for realizing digital manufacturing has been studied in this paper. The main research results are as follows.
1. Based on the meshing theory of spiral bevel gears, the shortcomings of the existing machine-settings calculation algorithm of Cyclo-Palloid spiral bevel gears have been improved. By setting the major axis length of the instantaneous contact ellipse and according to the curvature parameters at reference point of engaged tooth surface, the offset value EXB of the axis of outer cutter head for modifying tooth lengthwise curvature is determined using iterative algorithm. By controlling the offset distance EXF of the axis of outer cutter head to ensure the tooth thickness, avoiding the helical angle and curvature deviation generated by the existing algorithms. Based on the KN3028, KN3030 standards and the improved algorithms, computer-aided design software is developed, and the software calculation results are verified through examples.
2. Based on the gear meshing theory, the tooth surface equation and the calculation method for tooth surface curvature parameters of Cyclo-Palloid spiral bevel gears is established. According to the tooth surface equation and the curvature parameters of the gearset, tooth contact analysis method for Cyclo-Palloid spiral bevel gears is established. It can not only analyze the contacting status of gearset at the theoretical installation location, but also obtain the shape of contact pattern, the curve of transmission error and the adjusting value of V, H while the gearset engaging at heel, midpoint and toe location. The machine-settings calculation algorithm and tooth contact analysis method are verified through the actual processing experiments.
3. Based on the tooth surface equation, the formulas are given for calculating the position vector and normal vector of the discrete points, while the discrete points are in the machine adjusting location or the generating location. An accurate method for calculating start and end generating cradle angle is proposed. Furthermore, a tooth form analysis method is proposed and the influence rule and its extent of various machine setting parameters on the tooth form is analyzed. On this basis, a method for modifying the tooth form errors is presented. According to the measured data, we can obtain the correction value of machine-setting parameters by which modify the tooth form errors generated by machining errors or compensate the tooth deformation generated by heat treatment.
4. Based on the CNC machining principle of Cyclo-Palloid spiral bevel gears, a new structure for workpiece spindle is proposed. It can realize the adjustment of offset distance and the continuous changes of direction angle of outer cutter head axis. Based on the motion transforming principle between CNC machine and mechanical machine and the machining coordinate system of H1600K CNC cutting machine, the mathematical model for CNC machining is established. By using this mathematical model and the "electronic gear" function of numerical control system, NC code can be generated, thus achieving CNC machining of Cyclo-Palloid spiral bevel gears.
5. Based on the model of H1600K CNC Cyclo-Palloid spiral bevel gear cutting machine, the structure of the on-machine measuring system is proposed. Considering the shortcomings of measuring principle of CMM and gear measuring center when inspecting the pinion, an on-machine measuring method of tooth forms errors based on generating principle is proposed. The tooth form errors can be measured without interference by using the probe with smaller diameter. The on-machine measuring procedure and data processing method for indexing precision and tooth form errors are given. Based on the secondary development platform of AutoCAD, simulation software is developed. By comparing the simulated measuring results with theoretical analysis results, the correctness of the on-machine measuring principle is verified.
1、基于螺旋锥齿轮传动的啮合理论,对现有摆线齿锥齿轮切齿算法的不足之处进行了改进。通过设定相啮合齿面在参考点处接触椭圆的长轴长度,根据齿面参考点的曲率参数,运用迭代算法确定了外刀盘修正齿长曲率时的偏距EXB。通过控制外刀盘回转中心的偏距EXF保证了轮齿的齿厚,避免了现有算法产生的螺旋角偏差和曲率偏差。基于KN3028、KN3030标准和改进后的切齿算法,开发了计算机辅助设计软件,并通过实例对软件的计算结果进行了验证。
2、基于齿轮啮合理论,建立了摆线齿锥齿轮的齿面方程以及齿面曲率参数的计算方法。根据大、小轮的齿面方程及齿面的曲率参数,建立了摆线齿锥齿轮齿面接触分析的方法,不仅可以分析齿轮副在理论安装位置时的接触情况,还可以得到齿轮副在齿面大端、中点、小端啮合时的接触区、传动误差曲线以及V、H调整量。通过实际的切齿加工实验,验证了切齿算法和齿面接触分析方法的正确性。
3、基于摆线齿锥齿轮的齿面方程,给出了齿面各离散点在机床调整位置以及在展成加工位置时的径矢和法矢的计算公式,并提出了一种精确计算展成起始和展成终止摇台角的算法。此外,建立了一种齿形分析的方法,并分析了各种机床调整参数对齿形的影响规律及影响程度。在此基础上,建立了一种修正齿形误差的方法,根据测量数据,可得到修正切齿加工误差或补偿热处理变形的机床调整参数修正量。
4、基于摆线齿锥齿轮的数控加工原理,提出了一种新的刀具主轴结构,可实现外刀盘轴线偏距的调整以及外刀盘轴线偏置方向角的连续调整。基于数控机床与机械式机床运动变换的原理以及H1600K型数控机床的数控加工坐标系,建立了摆线齿锥齿轮数控加工的数学模型。利用该数学模型以及数控系统的“电子齿轮”功能,可生成数控加工的程序代码,进而实现摆线齿锥齿轮的数控加工。
5、基于H1600K型数控摆线齿锥齿轮铣齿机,提出了在机测量系统的结构。针对CMM和齿轮测量中心测量小轮时存在的问题,提出了基于展成原理的齿形误差在机测量方法,可利用小直径测球的直测针无干涉地完成齿面的测量。给出了齿形误差和齿轮分度精度的在机测量过程以及测量数据的处理方法。基于AutoCAD的二次开发功能,开发了仿真软件,通过对比仿真测量结果和理论分析结果,验证了在机测量原理的正确性。
Cyclo-Palloid spiral bevel gears are the key components of the large or heavy mechanical equipment for transmitting motion and power between intersecting axes. At present, CNC machining equipment and digital manufacturing technologies of Cyclo-Palloid spiral bevel gears are still owned by Klingelnberg Corporation in Germany. But in the field of CNC machining equipment and manufacturing technologies, the domestic companies are still in the initial stage. In order to improve the independent innovation capacity of CNC machining equipment and enhance the digital manufacturing level of Cyclo-Palloid spiral bevel gears, the CNC machining equipment and key technologies for realizing digital manufacturing has been studied in this paper. The main research results are as follows.
1. Based on the meshing theory of spiral bevel gears, the shortcomings of the existing machine-settings calculation algorithm of Cyclo-Palloid spiral bevel gears have been improved. By setting the major axis length of the instantaneous contact ellipse and according to the curvature parameters at reference point of engaged tooth surface, the offset value EXB of the axis of outer cutter head for modifying tooth lengthwise curvature is determined using iterative algorithm. By controlling the offset distance EXF of the axis of outer cutter head to ensure the tooth thickness, avoiding the helical angle and curvature deviation generated by the existing algorithms. Based on the KN3028, KN3030 standards and the improved algorithms, computer-aided design software is developed, and the software calculation results are verified through examples.
2. Based on the gear meshing theory, the tooth surface equation and the calculation method for tooth surface curvature parameters of Cyclo-Palloid spiral bevel gears is established. According to the tooth surface equation and the curvature parameters of the gearset, tooth contact analysis method for Cyclo-Palloid spiral bevel gears is established. It can not only analyze the contacting status of gearset at the theoretical installation location, but also obtain the shape of contact pattern, the curve of transmission error and the adjusting value of V, H while the gearset engaging at heel, midpoint and toe location. The machine-settings calculation algorithm and tooth contact analysis method are verified through the actual processing experiments.
3. Based on the tooth surface equation, the formulas are given for calculating the position vector and normal vector of the discrete points, while the discrete points are in the machine adjusting location or the generating location. An accurate method for calculating start and end generating cradle angle is proposed. Furthermore, a tooth form analysis method is proposed and the influence rule and its extent of various machine setting parameters on the tooth form is analyzed. On this basis, a method for modifying the tooth form errors is presented. According to the measured data, we can obtain the correction value of machine-setting parameters by which modify the tooth form errors generated by machining errors or compensate the tooth deformation generated by heat treatment.
4. Based on the CNC machining principle of Cyclo-Palloid spiral bevel gears, a new structure for workpiece spindle is proposed. It can realize the adjustment of offset distance and the continuous changes of direction angle of outer cutter head axis. Based on the motion transforming principle between CNC machine and mechanical machine and the machining coordinate system of H1600K CNC cutting machine, the mathematical model for CNC machining is established. By using this mathematical model and the "electronic gear" function of numerical control system, NC code can be generated, thus achieving CNC machining of Cyclo-Palloid spiral bevel gears.
5. Based on the model of H1600K CNC Cyclo-Palloid spiral bevel gear cutting machine, the structure of the on-machine measuring system is proposed. Considering the shortcomings of measuring principle of CMM and gear measuring center when inspecting the pinion, an on-machine measuring method of tooth forms errors based on generating principle is proposed. The tooth form errors can be measured without interference by using the probe with smaller diameter. The on-machine measuring procedure and data processing method for indexing precision and tooth form errors are given. Based on the secondary development platform of AutoCAD, simulation software is developed. By comparing the simulated measuring results with theoretical analysis results, the correctness of the on-machine measuring principle is verified.
引文
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