Spiral bevel gears are key components of aviation power transmission systems, and their machining accuracy directly affects the meshing quality of spiral bevel gear pairs and the transmission performance of the entire transmission system. At present, spiral bevel gears can be divided into five knife method and full process method according to different machining methods for small wheels. Compared with traditional five knife method, full process method has the advantage of high machining efficiency and has become the mainstream machining method. Therefore, this article will study the full process machining of spiral bevel gears. In recent years, Zhang Yu has conducted research on the calculation of machining parameters for spiral bevel gears using the full process method; Yan Hongzhi studied the influence of installation position on meshing performance of spiral bevel gear pairs processed by full process method; Yang Yu [8] conducted a full process machining study using a four axis linkage CNC gear milling machine, and analyzed the machine tool error sensitivity, providing technical support for the full process machining of spiral bevel gears.
The development of CNC bevel gear milling machines provides more possibilities for the realization of the design performance of spiral bevel gears, and provides a guarantee for various comprehensive modifications and corrections in tooth surface machining. Stadtflew H J proposed the concept of universal motion concept (UMC); Zeng Tao and Fan Qi introduced the expression of machine tool adjustment parameter motion as a function of shaking table motion parameters, increasing the freedom of machining; Zhang Weiqing conducted a research on motion control methods for fully controlled bevel gear milling machines, and then proposed using higher order motions of gear cutting parameters to achieve the effect of tooth surface trimming generated by tool trimming to improve the transmission performance of gear pairs. Cao Xuemei and Su Jinzhan have completed the tooth surface design of spiral bevel gears with high order transmission errors, accurately controlling the contact performance of the tooth surface.
The above research on tooth surface modification is mainly aimed at the machining of spiral bevel gears using the five tool method. For the full process method, Wang PY and Fan Qi completed the tooth surface modification processing using the higher order polynomials of processing parameters. Yan Hongzhi completed the tooth surface error correction technology for spiral bevel gears. Sun Jiayao conducted a full process method grinding and machining tooth surface error correction research for non orthogonal spiral bevel gears.
When machining spiral bevel gears using the full process method, the two surfaces use the same set of processing parameters, and the two surfaces affect and restrict each other during correction. In order to achieve collaborative correction machining using the double-sided method, based on previous research, this paper proposes to equivalently convert the adjustment parameters of the machine tool for machining spiral bevel gears using the full process method into the form of six-order polynomial expression of the movement axis of the CNC machine tool, introduce weight coefficients to the working surface, and optimize the six-order polynomial coefficients to reduce the error of the double-sided machining tooth surface and ensure the machining quality of the tooth surface.