Digital simulation method of cylindrical gear hobbing process

The new digital simulation method of cylindrical gear hobbing process is proposed. By analyzing the position relationship between the hob and the workpiece, the three-dimensional spatial meshing simulation model of the hob and the cylindrical gear is established, and the angular relationship between the hob and the gear in the cylindrical gear hobbing process is analyzed. By solving the intersection of the normal of the gear tooth surface and the involute spiral surface of the gear hob, On this basis, the tooth profile of cylindrical gear hobbing is simulated. The feasibility and correctness of the proposed method are verified by comparing the simulated tooth profile with the theoretical involute tooth profile. Using the proposed simulation model of cylindrical gear hobbing, the simulation test is carried out on the installation axis intersection error of modified gear and hob.

The main work is as follows:

(1) The structural parameters of the hob are determined, including the selection of the basic worm of the hob and the selection principle of the gear hob. The installation requirements of the hob, the adjustment of the installation angle and the determination of the axial position of the hob are introduced. The gear errors are classified according to the main sources of the cylindrical gear hobbing error and the gear rotation direction when the error occurs.

(2) The coordinate system of hob involute helicoid and spur gear is established, and the parameter equations of hob and spur gear are deduced. Based on Mathematica software, combined with the specific basic parameters of hob and gear, the three-dimensional model of hob involute helicoid and spur gear tooth surface is simulated, which provides the preliminary conditions for the digital simulation of cylindrical gear hobbing.

(3) A new digital simulation method of cylindrical gear hobbing process is proposed. Through the coordinate transformation matrix, the gear tooth surface coordinate system is transformed into the hob coordinate system, and then the gear tooth surface after coordinate transformation and the hob involute helical surface are combined together, which is the three-dimensional meshing simulation model of cylindrical gear hobbing. By analyzing the rotation angle relationship between hob and gear in the process of cylindrical gear hobbing, the intersection of gear tooth surface normal and hob involute helical surface is solved, and the simulated tooth profile of cylindrical gear hobbing is obtained. By comparing the simulated tooth profile with the theoretical involute tooth profile, the error value is less than 0.5 μ m. The feasibility of the proposed simulation method for cylindrical gear hobbing is verified

And correctness. By giving two groups of basic parameters of hobs and gears, the universality of the proposed digital simulation method for cylindrical gear hobbing process is verified.

(4) The application test of the proposed digital simulation method of cylindrical gear hobbing process is carried out. Using the simulation model of cylindrical gear hobbing, the simulation tests of positive and negative modified gears are realized by increasing or reducing the center distance between hob and gear, and the error value between simulated tooth profile and theoretical tooth profile is obtained. By changing the hob installation axis intersection angle to realize the simulation test of axis intersection angle error, compare the simulated tooth profile with the theoretical tooth profile, get that the existence of installation axis intersection angle error will cause the asymmetry of the machined gear tooth profile, and get the error value between the simulated tooth profile and the theoretical tooth profile under different axis intersection angle errors.

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