准双曲面齿轮数控成形铣齿机的设计与干式切齿实验研究

河南科技大学硕士学位论文准双曲面齿轮数控成形铣齿机的设计与干式切齿实验研究姓名：王明海申请学位级别：硕士专业：机械设计及理论指导教师：邓效忠20100501IIIISubject:DesignofCNCformatemillingmachineofhypoidgearandTheexperimentofdrycuttingSpecialty:MechanicalDesignandTheoryName:WangMinghaiSupervisor:DengXiaozhongABSTRACTHypoidgearisacriticalpartwhichiswidelyusedinautomobilechassistransmission.Withtherapiddevelopofourcountry’smotor-dom,thedemandofthehypoidgearmultiplies.Atthepresent,thegearmillingmachinewhichusedampprocessingiswidelyusedinourcountry,butthecuttingefficiencyislow.So,itisnecessrytodevelopadrycuttingmillingmachine,whichisenergyconservationandenvironmentprotectionandwillincreasetheefficiencyandmakeprocessingeasier.Thesecontentshavebeendiscussedinthispaper:1.Basedontheprincipleandmethodofspiralbevelandhypoidgearsgenerating,themathematicalmodelofcuttinghypoidgearinthemachinehasbeensetedup.Andthemovementofprocessingparametersaresolved.Theprincipleofhighspeeddry-typecuttinghasbeenintroduced.Thenthemechanicalstructuredesignsofmachinetoolhavebeendone,2.Designedthemachinestructure.Accordingtotherequirementsofdrycuttingtomachinetools’performance,partsofmachineoptimizationwereimproved.Suchastheuseofthewholebed,8speedtoolbox,variableleadwormgearindexing,automaticchipremovaldevices.Atlastmachinemechanicalstructuredesignwascompleted,thepartsdiagramwasdrawedfortheproduction.3.Thehydraumaticpartofthemachinehasbeendesigned.Theworkingconditionofmachinehasbeenanalysed,andaccordingtotheactualmovementrequestofmachine,theThenumericalcontrolofthemachinehasbeenchosenreasonably,thenthemachinetoolcircuitandtheelectriclacabinetshavebeendesigned,andthecircuitschematicsofmachinehavebeendrawtorealizethesemi-numericallyprocessingofworkpiece.4.Theprototypehasbeenassembled,andtheexperimenthasbeendonetoinspectperformance,machiningaccuracyandefficiencyofthemachine.ThetestprovedthattheNCmillingmachinecanmeettheneedsofdrycutting,IVandtheroughcutefficiencyofthewheelhypoidgearsincreases5times,andthemachinehasmoreadvantages,suchashighstrength,highefficiency,easytooperateandinexpensive,andsoon..Thescheduleddesignrequirementshavebeenachieved.KEYWORDS:hypoidgearsformmachinedrycuttinggearmillingmachineCNCDissertationType:applicationresearch111.1[1][2][3]21.21.2.1[5]150234Gleason[6]1.2.2GleasonE.Wildaber[7-10]402060GleasonM.L.Baxter[11-13]F.L.Litvin[14-22]2060Gleason1913GleasonJames.Gleason131925No.16HGleason1954GleasonNo.116()2080GleasonPhoenixCNCFree-form41.2.3[23][24-30][31-35][36-37][538]1999YH224019992001YK2212YK2245YKD2212YKD228020051250mmYH6012[39]15GleasonNo1116/118No126No1463Y221.31.3.1114~17%217288392.63.6930%0.51kWh2kWh25%75%[40]3(DryCutting)[41-43]61.3.21.3.3902007275HC2008C600HC[40]1.4[44]2008934.593820091379.101364.4848.30%46.15%20%[45]17[29][46][47]95%70801.51234282.12.1.1[48~50]12932.1.2901931(2-1)()210[51]2-1Fig.2-2salomoncurve51090%1230395984562.1.31[41]-10~-10011(-10~-100)2(C02)2.22-22-32-40d°0d≠°2122-2Fig.2-2Designprincipleofhypoidgearmachinetool2-3[5]90o132-4Fig.2-4ConeGeneratingGear2-5Fig.2-5therelativepositionofthetoolofGearmesh2-5MMMM2-6M01d2142-6Fig.2-6Theformoftoothlocalizedcontact2.32.3.1152.3.2350450mm350152.4r=mm510100m/min310010/(2152.4)104.5/np≥×××=104.5/2.42.4.12162-7Free-formFig.2-7Free-form3dconceptualmodelofhypoidgearmachinetoolFig.2-8TheschematicofCNCmachine-toolsofspiralbevelgears172-8XXXYYAZZZA2.4.22-9SmOmXmOmYm2-9Fig.2-9Thecoordinatesystemof4-axisCNCmachinetools218StOtXtOtYtStSmXmSmYmxySmSaSbSaSmZmSbSaSaOaXbSaXa??SpSpSbSbXbL2-9()()CptpbbaammtMMMMM=100010000100001pbLM-⎡⎤⎢⎥⎢⎥=⎢⎥⎢⎥⎣⎦cos0sin00100sin0cos00001baMgggg⎡⎤⎢⎥⎢⎥=⎢⎥-⎢⎥⎣⎦100001000010001amMz⎡⎤⎢⎥⎢⎥=⎢⎥-⎢⎥⎣⎦10001000100001mtxyM⎡⎤⎢⎥⎢⎥=⎢⎥⎢⎥⎣⎦19()()cos0sincossin010sin0cossincos0001CptxzLYMxzgggggggg--⎡⎤⎢⎥⎢⎥=⎢⎥--⎢⎥⎣⎦()()cossin[0001]sincos1cTptptxzLYOOMxzgggg--⎡⎤⎢⎥⎢⎥==⎢⎥-⎢⎥⎣⎦uuuuur()()cos0sin010sin0cosCptLgggg⎡⎤⎢⎥=⎢⎥⎢⎥-⎣⎦2.53203.13.1.13-13-1Fig.3-1ThesketchofCNCmachine-toolsstructureofHypoidgears2112XY3XCXY4ZB3.1.21170mm322234567893Tab.3-1TechnicalparametersofCNCmachine-toolsmmmm16inchKg75003.23.2.123343.2.213-23-2Fig.3-2ThelevelprofileofMachinetoolbed23-33243-3Fig.3-3TheverticalprofileofMachinetoolbed3-4Fig.3-4Machinetoolbed3[52]Z25HT2503.33-5Fig.3-5Thethicknessofwormgear326Fig.3-6ThediagramofcylinderhydrauliccylinderZBZ3.4Y360273.4.118?16?12?9?7.5?6?3.4.21430r/min980r/min53-722.53244.761.565.189.8122.3178.5r/min—3-73-85Fig.3-7TransmissionsystemofcutterboxFig.3-8Revolutionspeeddiagramoffivestepstransmissionsystem32815/3523/2727/2335/153-83.4.324681013579zzzzzizzzzz××××=××××zz24681013579533335294343.631824151815zzzzzizzzzz××××××××===××××××××zi=21..95zi=15.93zi=8.013.4.435152753332943232318241815271535⎧⎫⎪⎪⎪⎪⎪⎪⎪⎪→→→→→→⎨⎬⎪⎪⎪⎪⎪⎪⎪⎪⎭⎩8/z5=15z6=36980r/min/z5=15z6=351430r/min/z5=23z6=27980r/min29/z5=23z6=271430r/min/z5=35z6=15980r/min/z5=35z6=151430r/min/z5=27z6=23980r/min/z5=27z6=231430r/min3.5[53]123453.5.1Z[49-51]33012345673-9ZFig.3-9ThesketchofCNCgearmillZ-axisstructureZ3-97764432Z3.5.21[54~55](1)(2)31(3)(4)(5)2ZX3.5.3ZFYND6310-63.6Z第4章数控成形铣齿机控制系统设计32第4章数控成形铣齿机控制系统设计液压与电控系统是数控铣齿机的重要组成部分，是铣齿机的指挥系统。成形法加工准双曲面齿轮大轮时，加工时只需进给方向（Z方向）移动、工件旋转轴（A轴