In the field of gear manufacturing, the efficiency and precision of processing techniques are of great importance. Traditional methods of manual chamfering and manual input of NC machining codes are becoming increasingly difficult to meet the requirements of modern production and processing, and automated chamfering technology is gradually gaining attention. This article focuses on the secondary development of spiral bevel gear tooth top chamfering software based on the FAGOR CNC 8070 – OL numerical control system.
The background and significance of this research lie in the need to improve the automation and precision of gear processing. With the development of modern manufacturing, the demand for high – efficiency and high – quality gear production is increasing. Automated chamfering technology can not only improve the processing efficiency and quality but also reduce the labor intensity and production costs. The FAGOR CNC system is widely used in the field of numerical control, and its secondary development can better meet the specific needs of users and improve the performance and functionality of the system.
Previous studies on numerical control system secondary development have made some progress, but there is still a lack of research on the secondary development of the FAGOR numerical control system. Therefore, this research aims to fill this gap and provide a reference for the development of related technologies.
The main content of this research includes the solution of the chamfering trajectory of spiral bevel gears, the development of the automated tooth top chamfering processing software, and the simulation and verification of the software.
- Solution of the Chamfering Trajectory of Spiral Bevel Gears
- Solution of the Equation of the Tooth Top Chamfer Line: To develop the tooth top chamfering software for spiral bevel gears, it is necessary to first solve the parametric equation of the chamfering trajectory. The equation of the tooth top chamfer line can be obtained from the literature, and the tooth thickness of the spiral bevel gear can be calculated using the formula. Based on this, the equation of the tooth top chamfer line can be derived.
- Solution of the Tool Trajectory Equation: By combining the end face involute tooth profile equation and the tooth top circle equation of the spiral bevel gear, the angles AJK and λ1 can be calculated. Then, in the triangle AFK, the coordinates of point F in the local coordinate system can be obtained. Finally, through the coordinate transformation matrix, the coordinates of point F based on the workpiece coordinate system can be calculated, and the rotation angles of the B and C axes can be solved.
| Trajectory Aspect | Details |
|---|---|
| Tooth Top Chamfer Line | The equation of the tooth top chamfer line is derived based on the equations from the literature and the tooth thickness formula. |
| Tool Trajectory | The coordinates of point F in the local coordinate system and the workpiece coordinate system are calculated, and the rotation angles of the B and C axes are solved. |
- Development of Spiral Bevel Gear Automated Tooth Top Chamfering Processing Software
- Basic Process of Secondary Development of CNC8070 – OL: The secondary development is based on the FGUIM software provided by FAGOR. A third – party software, the spiral bevel gear automated tooth top chamfering processing software, is developed using VB.net for the human – machine interface design and C++ for the parameter calculation logic program. The software is connected to the CNC8070 – OL numerical control system through FGUIM, and the software is embedded into the numerical control system to realize functions such as parameter calculation, NC code generation, and database management.
- Human – Machine Interface Development of the Spiral Bevel Gear Automated Tooth Top Chamfering Processing Software: The human – machine interface is developed using VS2015. The main steps include creating a new Visual Basic form application, adding controls to the interface, referencing the COM components written in C++, connecting to the CNC8070 – OL numerical control system, and saving the file as an.exe file.
- Main Function Modules of the Spiral Bevel Gear Automated Tooth Top Chamfering Processing Software: The software consists of seven modules: gear parameters, process parameters, parameter calculation, program generation, program management, alarm, and status. The software uses the Microsoft Access 2010 database as the data support to facilitate the exchange of information with the numerical control system.
- Implementation of Automatic Generation of NC Machining Program Codes: The automatic generation of NC machining program codes is the most important function of the software. In the C++ development environment, a COM component is developed by following specific steps, including creating an ATL project, adding classes and methods, and registering the component. The generated NC machining codes are stored in the Microsoft Access 2010 database along with the input parameters and time stamps for easy retrieval and use.
| Software Development Aspect | Details |
|---|---|
| Basic Process | The secondary development is based on FGUIM, and a third – party software is developed using VB.net and C++. The software is connected to the numerical control system through FGUIM and embedded into the system. |
| Human – Machine Interface | Developed using VS2015, including creating a form application, adding controls, referencing COM components, connecting to the numerical control system, and saving the file. |
| Main Function Modules | Consists of seven modules, and uses the Microsoft Access 2010 database for data support. |
| NC Code Generation | A COM component is developed in the C++ environment, and the generated codes are stored in the database. |
- Simulation and Verification
- Simulation: The left and right chamfering programs generated by the spiral bevel gear tooth top chamfering software are imported into the VERICUT simulation software for simulation. The simulation results show that the chamfering surface is smooth and uniform, and the sizes of the chamfers at both ends have good consistency.
- Error Analysis: Twenty points are evenly selected on the theoretically calculated chamfer line and the actual simulation chamfer line, and the data is imported into Origin to draw a line chart. The results show that the length error after the tool cutting does not exceed 0.045 mm, which meets the chamfering error requirements.
| Simulation and Verification Aspect | Details |
|---|---|
| Simulation | The chamfering programs are imported into VERICUT for simulation, and the results show a smooth and consistent chamfering surface. |
| Error Analysis | Points are selected on the chamfer lines for error analysis, and the results meet the error requirements. |
The main conclusions of this research are as follows:
- The solution of the tooth top chamfer line equation and the tool trajectory equation provides a theoretical basis for the secondary development.
- The specific process steps of the secondary development of the FAGOR CNC8070 – OL numerical control system using the mixed programming of C++ and VB.net are introduced. The embedding of the spiral bevel gear tooth top chamfering software into the FAGOR CNC8070 – OL numerical control system makes the operation more convenient and efficient, reduces the operational difficulty, and has a positive significance for promoting the chamfering processing of spiral bevel gears.
However, this research also has some limitations. For example, the software may need further optimization and improvement in terms of performance and functionality. Future research could focus on enhancing the accuracy and reliability of the software, as well as expanding its application scope.
In conclusion, this research provides a valuable approach for the development of spiral bevel gear tooth top chamfering technology, which can contribute to the improvement of gear processing quality and efficiency. Further research in this area can lead to more advanced and practical solutions in the field of numerical control and gear manufacturing.