Machining of large size and high precision spiral bevel gear

Spiral bevel gear is a key part in the field of mechanical transmission, which transmits motion or power between intersecting shafts or staggered shafts. In the transmission process, the gear teeth whistle gradually transition from one end to the other end. Compared with straight bevel gear and helical bevel gear, spiral bevel gear has many good properties, such as large overlap coefficient, high bearing capacity, stable transmission, low noise and so on. Due to the above advantages, spiral bevel gears are widely used in various mechanical products such as railway locomotives, ships, automobiles, tractors, large conveyors, roadheader, loaders and so on, which greatly improves the reliability and service life of these products and achieves good economic benefits.

There are two tooth systems for large-size spiral bevel gears. One is circular arc bevel gear with circular arc tooth line. The whole tooth slot shrinks or has equal height along the tooth rectangle, which is called tooth system. Tooth bevel gears can be ground after heating. The other is the cycloid quasi involute bevel gear whose tooth line is an extended epicycloid. The tooth height along the tooth rectangle is equal, which is called tooth system. Tooth bevel gears can scrape teeth after heating. The final accuracy of these two methods can reach more than grade.

In terms of application degree, spiral bevel gear is widely used abroad. It is a good power in the process of machine transmission and plays different roles in various fields. Due to its strong bearing capacity, it is suitable for the bearing process of large machinery, such as automobile, railway, ship and other mechanical products. In a specific sense, large gears have certain applicability, their diameter is generally more than 700mm, and there are high requirements for finished gears, which must reach level 5 or above, so the production has excellence and universality.

In foreign countries, large-scale high-precision helical gear is first proposed by a machine tool manufacturing enterprise in New York, USA. manufacturing enterprises are mainly used for automobile production. This mode is mainly molar machine, which is used for the management of large-scale CNC machine tools. In the later development, the factory improved this point, refined the precision of spiral bevel gear, heated it on the basis of precision machining, and polished it in the way of hanging teeth.

Large size spiral bevel gears with large diameter are mainly used for large reducers in mining, metallurgy, petroleum and other industries. With the rapid development of China’s heavy industry, the demand for large size spiral bevel gears is increasing. At present, most of the large size spiral bevel gears used in industry are programmed spiral bevel gears with side middleware, but the side middleware must be double cutter and half, Because of the complex structure of cutting tools and machine tools, it is difficult to manufacture. At present, only German companies have the manufacturing technology of Dr. fration bell gear multi shaft digital press and cutting machine. In order to break the monopoly of foreign enterprises on large-size spiral bevel gears and reduce manufacturing costs, this paper puts forward two solutions. First, the design of side spiral bevel gears is changed to the design of repair, which is simple in calculation and convenient in adjustment. Second, Taking advantage of the digital control lathe, the universal shaft linkage digital controller helical gear machine tool is adopted to directly process the integral shear plate of the design side middleware, which reduces the cost. This paper focuses on the design and manufacturing technology of two large-size helical bevel gears: circular arc equal height bevel gear and cycloid quasi involute bevel gear. According to the many years of working experience of ZHY Gear, The research of this kind of gear has a new understanding.

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