双圆弧齿轮滚刀CAD系统研究与开发
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摘要
双圆弧齿轮滚刀作为切削加工过程中的直接生产工具,其性能直接影响切削加工的效率,进而影响双圆弧齿轮的表面质量和精度,因此双圆弧齿轮滚刀的精确设计就显得尤为重要。
通过对双圆弧齿轮滚刀的设计原理和制造技术的分析,突破传统设计过程中以基准齿形作为双圆弧滚刀基本蜗杆法向齿形的设计方法,将双圆弧齿轮滚刀轴向齿形以基本蜗杆螺旋参数运动形成的螺旋面作为双圆弧齿轮滚刀基本蜗杆螺旋面。将CAD技术与双圆弧滚刀设计理论紧密结合,综合运用参数化特征技术和面向对象的模块化编程技术,利用SolidWorks二次开发技术设计双圆弧齿轮滚刀。
首先,以GB/T12759-1991双圆弧齿轮为例,根据空间双圆弧齿轮啮合原理,介绍了双圆弧齿轮滚刀的齿形计算过程。从双圆弧齿轮基本蜗杆齿面方程出发,先求出任意前角的双圆弧齿轮滚刀前刀面齿形,再根据铲磨加工时滚刀与砂轮的相对运动关系,求出砂轮轴向廓形。
其次,通过对齿轮滚刀造型误差的理论分析和探讨,提出影响双圆弧齿轮滚刀精度的主要因素,并确定双圆弧齿轮滚刀齿形设计方案。通过双圆弧齿轮滚刀齿形误差计算和造型优化,获得双圆弧齿轮滚刀铲磨砂轮最优设计参数,并且阐述了双圆弧齿轮滚刀三维参数化造型过程。
再次,在分析双圆弧齿轮滚刀铲磨原理的基础上,利用造型优化后的砂轮设计参数,在VERICUT中对双圆弧齿轮滚刀铲磨加工过程进行加工仿真,通过对比分析仿真结果中滚刀实际刃形与理论刃形,以此来检验双圆弧齿轮滚刀设计方案的可行性。
最后,建立双圆弧齿轮滚刀CAD系统总体框架,采用功能模块的设计思想,把整个系统分成了双圆弧齿轮滚刀设计计算、双圆弧齿轮滚刀设计图形处理、双圆弧齿轮滚刀铲磨加工仿真、双圆弧齿轮滚刀刀齿有限元分析、齿轮刀具数据库管理五个模块。
Double circular-arc gear hob is a direct production tool in machining process, whose performance directly affects the machining efficiency,and then affects surface quality and accuracy of double circular-arc gear.Thereby,the precise design of double circular-arc gear hob is of particularly importance.
Through analyzing the design principle and manufacturing technology of double circular-arc gear hob,a breakthrough is made in design method.In traditional design process,baseline profile is used as the normal tooth profile of double circular-arc gear hob's basic worm,and axial tooth profile of double circular-arc gear hob uses helicoid formed by the movement in accordance with helical parameters of basic worm as helicoid of double circular-arc gear hob.With the close combination of the application of CAD technology and design theory,as well as the comprehensive utilization of parameterized feature modeling technology and object-oriented modular technology,the CAD system design of double circular-arc gear hob is achieved by secondary development of SolidWorks.
Firstly,the calculation process of double circular-arc gear hob's tooth profile is introduced according to gear meshing theory,the GB/T12759-1991 double circular-arc gear hob as example.Start with tooth surface equation of double circular-arc gear's basic worm,rake face of double circular-arc gear hob at any front angle is obtained.And then axial profile of relief grinding wheel is gained according to relative kinematic relation between grinding wheel and hob in relief grinding.
Secondly,through discussing the theory of form errors of gear hob,the major factors that impact the accuracy of double circular-arc gear hob is summed up,and the design scheme of double circular-arc gear hob tooth profile is ensured.Through error calculation of tooth profile and optimization of modeling,the grinding wheel's optimal design parameters of double circular-arc gear hob are obtained.And the parametric modeling process of double circular-arc gear hob is expounded.
Thirdly,on the base of analyzing grinding principle of double circular-arc gear hob,the wheel shape's design parameters are taken advantage of.And machining simulation of relief grinding process of double circular-arc gear hob is carried out in VERICUT.The actual tooth profile is compared to theoretical form in order to verify the feasibility of design scheme.
Finally,the overall framework of CAD system is established.Function module design ideas are adopted in this system,and the whole system is divided into five modules,such as the design and calculate of double circular-arc gear hob,the graphics processing of hob's design,relief grinding machining simulation of hob,the element analysis of hob cutter tooth,tool's database management.
通过对双圆弧齿轮滚刀的设计原理和制造技术的分析,突破传统设计过程中以基准齿形作为双圆弧滚刀基本蜗杆法向齿形的设计方法,将双圆弧齿轮滚刀轴向齿形以基本蜗杆螺旋参数运动形成的螺旋面作为双圆弧齿轮滚刀基本蜗杆螺旋面。将CAD技术与双圆弧滚刀设计理论紧密结合,综合运用参数化特征技术和面向对象的模块化编程技术,利用SolidWorks二次开发技术设计双圆弧齿轮滚刀。
首先,以GB/T12759-1991双圆弧齿轮为例,根据空间双圆弧齿轮啮合原理,介绍了双圆弧齿轮滚刀的齿形计算过程。从双圆弧齿轮基本蜗杆齿面方程出发,先求出任意前角的双圆弧齿轮滚刀前刀面齿形,再根据铲磨加工时滚刀与砂轮的相对运动关系,求出砂轮轴向廓形。
其次,通过对齿轮滚刀造型误差的理论分析和探讨,提出影响双圆弧齿轮滚刀精度的主要因素,并确定双圆弧齿轮滚刀齿形设计方案。通过双圆弧齿轮滚刀齿形误差计算和造型优化,获得双圆弧齿轮滚刀铲磨砂轮最优设计参数,并且阐述了双圆弧齿轮滚刀三维参数化造型过程。
再次,在分析双圆弧齿轮滚刀铲磨原理的基础上,利用造型优化后的砂轮设计参数,在VERICUT中对双圆弧齿轮滚刀铲磨加工过程进行加工仿真,通过对比分析仿真结果中滚刀实际刃形与理论刃形,以此来检验双圆弧齿轮滚刀设计方案的可行性。
最后,建立双圆弧齿轮滚刀CAD系统总体框架,采用功能模块的设计思想,把整个系统分成了双圆弧齿轮滚刀设计计算、双圆弧齿轮滚刀设计图形处理、双圆弧齿轮滚刀铲磨加工仿真、双圆弧齿轮滚刀刀齿有限元分析、齿轮刀具数据库管理五个模块。
Double circular-arc gear hob is a direct production tool in machining process, whose performance directly affects the machining efficiency,and then affects surface quality and accuracy of double circular-arc gear.Thereby,the precise design of double circular-arc gear hob is of particularly importance.
Through analyzing the design principle and manufacturing technology of double circular-arc gear hob,a breakthrough is made in design method.In traditional design process,baseline profile is used as the normal tooth profile of double circular-arc gear hob's basic worm,and axial tooth profile of double circular-arc gear hob uses helicoid formed by the movement in accordance with helical parameters of basic worm as helicoid of double circular-arc gear hob.With the close combination of the application of CAD technology and design theory,as well as the comprehensive utilization of parameterized feature modeling technology and object-oriented modular technology,the CAD system design of double circular-arc gear hob is achieved by secondary development of SolidWorks.
Firstly,the calculation process of double circular-arc gear hob's tooth profile is introduced according to gear meshing theory,the GB/T12759-1991 double circular-arc gear hob as example.Start with tooth surface equation of double circular-arc gear's basic worm,rake face of double circular-arc gear hob at any front angle is obtained.And then axial profile of relief grinding wheel is gained according to relative kinematic relation between grinding wheel and hob in relief grinding.
Secondly,through discussing the theory of form errors of gear hob,the major factors that impact the accuracy of double circular-arc gear hob is summed up,and the design scheme of double circular-arc gear hob tooth profile is ensured.Through error calculation of tooth profile and optimization of modeling,the grinding wheel's optimal design parameters of double circular-arc gear hob are obtained.And the parametric modeling process of double circular-arc gear hob is expounded.
Thirdly,on the base of analyzing grinding principle of double circular-arc gear hob,the wheel shape's design parameters are taken advantage of.And machining simulation of relief grinding process of double circular-arc gear hob is carried out in VERICUT.The actual tooth profile is compared to theoretical form in order to verify the feasibility of design scheme.
Finally,the overall framework of CAD system is established.Function module design ideas are adopted in this system,and the whole system is divided into five modules,such as the design and calculate of double circular-arc gear hob,the graphics processing of hob's design,relief grinding machining simulation of hob,the element analysis of hob cutter tooth,tool's database management.
引文
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[4]吴洁,蔡春源.基于跑合性能的双圆弧齿轮齿形参数优化设计[J].煤矿机械,2001,(2):6-7
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[6]韩振南,李进宝.硬齿面双圆弧齿轮滚刀的齿面方程及二次刀具廓形设计[J].中国机械工程,2002,13(11):910-912
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[9]何迎霞.铲磨滚刀的砂轮廓形的数字化计算方法[J].工业技术,2008,(03):33-34
[10]孙玉文等.基于误差补偿的刀具铲磨砂轮修形的数值模拟[J].中国机械工程,2000,11(12):1321-1323
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[14]J.Y.Fuh,C.H.Chang,M.A.Melkanoff.The development of an integrated and intelligent CAD/CAPP/CAPP environment using Logic-based reasoning[J],Computer-Aided Design,1996,28(3):217-232
[15]Zuo Bing Chen,Li D Xu.An Object-oriented intelligent CAD system for Ceramic Kiln[J],Knowledge-based System,2001,14:263-270
[16]Ping-Yi Chao,Yu-Chou Wang.A data exchange framework for networked CAD/CAM[J],Computer In Industry,2001,44:131-140
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[18]Mohamed El-Mehalawi,R.Allen Miller.A database system of mechanical components based on geometric and topological similarity[J].Computer-Aided Design,2003,(35):83-94
[19]卢贤缵,尚俊开.圆弧齿轮啮合原理[M].北京:机械工业出版社,2003,47-56
[20]李志胜,高红梅等.高硬齿面双圆弧齿轮滚刀的铲磨研究[J].机械传动,2006,30(3):16
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[22]杨老记,谷群广.齿轮滚刀造型误差的理论分析[J].工具技术,2003,39(8):30
[23]李雅青,常兴.直槽双圆弧齿轮滚刀的齿面特性分析[J].新技术新工艺,2000,(9):24-25
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