With the acceleration of China’s industrialization process, automobile, agriculture and construction machinery have higher requirements for the development of gear industry, and the demand for equal height spiral bevel gears with high precision is increasing. As a transmission part, equal height spiral bevel gear is widely used in the field of mechanical industry because of its advantages of stable transmission, reducing impact and noise. In this paper, the machining of equal height spiral bevel gear is studied, the theoretical analysis is carried out, the machining is simulated, and the cutting parameters are optimized based on genetic algorithm. The cutting experiment of equal height spiral bevel gear is completed with the optimized cutting parameters. The main conclusions are as follows:
- The machining principle of equal high tooth spiral bevel gear is analyzed. Through the meshing principle based on plane, the machining principle of equal high tooth spiral bevel gear is studied; By analyzing the hobbing method of tooth surface for machining equal height spiral bevel gear, the cutting surface equation of cutter head is obtained, the main cutting parameters are determined, and the structure of milling cutter head is optimized.
- The simulation of cutting process is completed. The three-dimensional model of cutter and equal height spiral bevel gear is established by using UG software; The simplified model is imported into ABAQUS software for simulation; The appropriate cutting parameters are determined through the analysis of cutting temperature and cutting force.
- The cutting parameters are optimized. The characteristics and basic operation of genetic algorithm are analyzed. By adding design variables, constraints and genetic algorithm parameters, and then according to the simulation results of cutting force and cutting temperature, multiple linear regression analysis method is used to fit the objective function, and Matlab genetic algorithm tool box is used to optimize the cutting parameters.
- The machining experiment of equal height spiral bevel gear is carried out by using the optimized cutting parameters. The milling cutter bar is ground and tested to meet the standard, and the overall cutter is assembled and debugged on the cutter loading machine; The cutting experiment of equal height spiral bevel gear is carried out on the machine tool; Detect the roughness, noise and accuracy of integral equal height spiral bevel gear. According to the output data, it is verified that the optimized cutting parameters can improve the machining accuracy and ensure the surface quality of equal height spiral bevel gear. It shows that the optimized cutting parameters can guide the machining of equal height spiral bevel gear and meet the needs of practical machining.
Due to the limitations of various factors, there are many deficiencies. For the simulation scheme can be closer to the actual processing situation, further research is needed.