The mapping law between machining system error, gear hobbing principle error, tool error, machine tool vibration and gear machining accuracy is studied. When the gear hobbing machine processes the gear workpiece, the machining accuracy will be lost due to many factors, resulting in the increase of scrap rate. In view of this problem, we carried out the research on the correlation law between the gear hobbing process and the geometric error of the tooth surface. The main work contents are as follows:
① The mapping relationship between gear hobbing machining system error and gear machining accuracy is studied. According to the actual situation of gear hobbing machining, the model of 24 position errors in gear hobbing machining is established from the aspects of installation error and motion error between tool and workpiece. The influence of each position error on gear machining accuracy is theoretically deduced, and the mapping relationship between 12 errors of hob and workpiece and gear hobbing machining accuracy is found.
② The mapping relationship between gear hobbing principle error and gear machining accuracy is studied. In the process of gear hobbing, the gear machining error caused by the gear hobbing principle is analyzed; The gear hobbing principle error is modeled, the mapping relationship between gear principle error and gear machining error is obtained, the relevant factors affecting gear machining error are found out, and the influence of various factors on gear hobbing machining accuracy is discussed. The gear hobbing machining process is simulated with MATLAB to show the causes of gear hobbing principle error.
③ The influence of tool error on gear machining accuracy is studied. Establish appropriate theoretical models for various errors of the tool and the gear workpiece, and then study the mapping relationship between various errors of the tool, including tooth profile error, helix error, tooth thickness error, radial circular runout error and rake face error on the gear machining accuracy according to the theoretical model and the gear meshing principle, and draw a conclusion; Then the theoretical involute and the involute machined by hob with error are simulated by MATLAB.
④ The influence of machine tool vibration on gear hobbing accuracy is studied. The structure of gear hobbing machine is modeled by vibration theory. Through the analysis of the model, some factors affecting the machining accuracy of gear hobbing machine are obtained, and some suggestions to reduce the response of machine tool are put forward to reduce the influence of machine tool vibration on gear hobbing accuracy; The influence of mechanical vibration on gear machining accuracy is deduced and verified by experiments; Finally, through the designed monitoring system, the machine tool processing is monitored in real time, so as to keep the machine tool in normal working state at all times.
Through the summary of the research content, it is considered that the research content needs to be improved and deepened from the following aspects:
① Whether the corresponding research contents can be further studied to obtain more accurate and valuable application results.
② Other factors affecting the machining accuracy of gear hobbing machine tool are also deeply studied. Finally, a comprehensive influence result is obtained by integrating various influencing factors, and relevant software is compiled to help complete the formulation of the machining plan of gear hobbing machine tool. It can reasonably formulate the machining plan according to the accuracy requirements, and complete the machining task economically, efficiently and with high qualification rate.