Breaking through the existing Gleason gear cutting system and based on the generation principle of spherical involute tooth surface, this paper innovatively puts forward a new method of cutting the tooth surface of spherical involute spiral bevel gear by taking the tooth surface generating line as the cutting edge and the inverse motion of the tooth surface generating motion as the cutting motion. Based on the research of three-axis linkage gear cutting method, some discrete points are used to approximately replace the tooth surface generation line, and based on the analysis of three-axis linkage gear cutting motion, the motion of point milling spiral bevel gear tooth surface is analyzed, and a new two-axis linkage spiral bevel gear machining method with simpler gear cutting motion is proposed. The main work of this paper is summarized as follows:
(1) The generation principle of tooth surface of spherical involute spiral bevel gear is analyzed. The following conclusions are drawn: the concave tooth surface is generated by pure rolling on the base cone from the large end to the small end and from the base cone to the face cone; The convex tooth surface is generated by pure rolling on the base cone from the small end to the large end and from the base cone to the face cone. The kinematic relationship of the generated tooth surface is calculated.
(2) Based on the generation principle of spherical involute spiral bevel gear tooth surface, the cutting generation motion of bevel gear tooth surface is analyzed. Taking the generating line of the tooth surface as the cutting edge and the inverse motion generated by the tooth surface as the cutting motion, the tooth surface of the spiral bevel gear can be cut only by three-axis linkage. The three linkage shafts are the rotation of the gear blank ω 1. The rotation of the gear blank around the end of the blade ω 2. Movement V of gear blank and gear blank along the boundary between cutting area and adjustment area. The speed relationship between the three must meet the formula.
(3) The three-axis linkage milling tool is designed. The key geometric parameters and structure design of the milling tool are analyzed, and the outer edge milling cutter for machining concave tooth surface and the inner edge milling cutter for machining convex tooth surface are designed. Compared with the existing spiral bevel gear cutting tools, the tool structure designed in this paper is greatly simplified, and the manufacturing and grinding are simple and convenient.
(4) The design of three-axis linkage gear cutting mechanism and the machining simulation of gear cutting are carried out. According to the analysis of three-axis linkage gear cutting motion, a three-axis linkage gear cutting mechanism is designed. The joint motion required by gear cutting is realized by base cone angle adjustment mechanism, horizontal rotation mechanism and moving mechanism respectively. Based on the analysis of gear cutting motion and the design of machine tool, the milling simulation of spiral bevel gear is carried out by using VERICUT simulation software, which verifies the feasibility of the designed gear cutting machine tool and the proposed new method of three-axis linkage gear milling.
(5) Based on the research of three-axis linkage gear cutting method, a new two-axis linkage point milling method with simpler gear cutting motion is proposed, the motion of two-axis linkage gear cutting is analyzed, and a two-axis linkage gear cutting scheme is studied. The simplified three-dimensional model of the key mechanism of spiral bevel gear two-axis linkage cutting machine tool is established by using CATIA software, and how to realize each movement required by spiral bevel gear tooth surface machining is analyzed.
(6) The gear cutting simulation of two axis linkage of spiral bevel gear is carried out. The models of gear cutting machine tool, cutting tool and gear blank are established by using VERICUT software, and then the NC program of spiral bevel gear machining is compiled by using MATLAB and Excel software. Finally, the gear cutting simulation is carried out in VERICUT environment. The new method of two axis linkage gear cutting of spiral bevel gear and the feasibility of the designed gear cutting machine tool are verified.
(7) The principle prototype of two axis linkage gear cutting machine tool is developed, and the gear cutting experiment is carried out. Based on xk716 CNC milling machine, the key functional components are added, the principle prototype of two-axis linkage CNC gear milling machine is developed, and the bevel gear blank is designed and processed. Finally, the tooth cutting experiment is carried out, and the sample of spiral bevel gear is cut. The tooth surface deviation of the processed bevel gear is measured by using 3906t gear measuring center. The measurement results show that the normal deviation of the tooth surface is between -0.0227mm ~ 0.0097mm, which further verifies the new method of two-axis linkage gear cutting.