In order to further improve the grinding efficiency of face gear, this paper presents a novel method for grinding face gear along contact trace using disk CBN wheel. Firstly, the grinding principle of face gear is studied, and the tooth surface equations of rack and gear shaper cutter are derived, thus formulating the tooth surface equation of disk CBN wheel. Secondly, considering the structure of the face gear grinding machine tool and the impact of the grinding wheel parameters on the face gear tooth surface, the disk CBN wheel configuration is proposed, and the calculation method of the tool position of the face gear grinding is established. Thirdly, according to the structural characteristics of the grinding wheel, the tooth surface contact trace of the face gear is designed, and the face gear development grinding processing method along the tooth surface contact traces is presented. Finally, a test of grinding spur face gear with disk CBN wheel is carried out on a laboratory-made five-axis face gear processing machine. The test results verified the correctness of the face gear grinding. Compared with the dish wheel for grinding face gear, the grinding method proposed in this paper can further improve the grinding efficiency of face gear. This method will break new ground for the engineering application of the face gear.

An efficient generation grinding method for spur face gear along contact trace using disk CBN wheel

Helical curve-face gear pair is a new type of gear pair consisting of a helical non-circular gear and a helical curve-face gear, which can transfer the movement of variable transmission ratio between intersecting axes. According to the spatial gear engagement theory and the spatial coordinate transformation theory, the transformation matrix of helical curve-face gear pair and the unit normal of helical cutter are deduced. Based on the meshing theory, the meshing equation of helical curve-face gear pair is built. Equations of instantaneous contact ratio of helical curve-face gear pair are proposed by transforming helical curve-face gear pair into helical non-circular rack and pinion. Besides, the influences of basic parameters of helical cutter and helical curve-face gear pair on contact ratio are analyzed. The tooth surface coordinate data of helical curve-face gear pair is obtained by using the gear measuring center, and the comparison findings between experimental and theoretical results are the experiment data basically agree with the theoretical calculation value, and error is within 5%, so the calculation method of contact ratio is verified.

Calculation and analysis of contact ratio of helical curve-face gear pair

As a new gear pair with variable transmission ratio, curve-face gear can be applied to percussion drill to simplify the structure. For the application of curve-face gear pair, the loaded tooth cont...

Loaded tooth contact analysis of curve-face gear pair:

The curve-face gear pair is a new type of gear pair, and it has not been widely applied in many occasions as other kinds of gear pairs. In order to solve the bending fatigue life problem of this new gear pair with time-varying characteristics, a new theoretical calculation model was established. According to the loading state in actual operation, the single-tooth force model of curve-face gear pair was built, the effective loading of curve-face gear was analyzed, and loading spectrum in a period tooth was obtained. By building tooth equivalent cantilever beam model, the single-tooth bending stress calculation formula was derived, and the bending stress spectrums in tooth different sections were analyzed, meanwhile stress spectrum of bending fatigue hazard section in a period tooth was obtained. Combining the Miner’s rule and bending stress spectrum of dangerous section position, the bending fatigue life calculation method of curve-face gear was proposed. Through concrete example analysis, the bending fatigue life of curve-face gear was calculated. According to dynamic load spectrum extracted by ADAMS and bending stress calculated by ANSYS Workbench, the fatigue damage distribution of curve-face gear was obtained by nCode DesignLife. By constructing curve-face gear pair running experimental platform, the dynamic tooth root bending stress was measured. Comparing the theoretical calculation, simulation, and experimental results, the error between experiment and theory is within 10%, so the theoretical calculation method of bending fatigue life of curve-face gear was verified.

Analysis and calculation of bending fatigue life of curve-face gear

The invention discloses a post-processing method for a non-orthogonal swinging head rotary table type five-axis machine tool. According to the method, the swinging head rotary table type five-axis machine tool regarding a translation axis Y and a revolution axis B as inclination axes is regarded as a research object, and structural characteristics of the type of the machine tool are analyzed; then, the included angle between the Y axis of the inclination axis and an OXZ plane and the pendulum length of a cutter are respectively regarded as variables, a motion transformation equation between pre-posed cutter spacing data and each coordinate axis of the machine tool is established, and a calculation formula of each coordinate axis is deduced. Based on this, post-processing software applicable to the type of the five-axis numerical control machine tool is developed by employing the C++ language, cutter spacing files can be converted to numerical control programs capable of being recognized by the machine tool, and five-axis cutter length compensation, work piece origin offset compensation function, and non-orthogonal axis angle correction can be realized in the numerical control programs.

Post-processing method for non-orthogonal swinging head rotary table type five-axis machine tool

In order to verify the validity of the design for the orthogonal variable transmission ratio face gear pair, a five-axis CNC machine tool was used to machine this gear. The cutter tooth profile coordinate system, orthogonal variable ratio face gear machining coordinates, the model for the round-corner at tooth tip, the contact line model and CNC machining models were established by using space gear meshing theory and the machining principle of five-axis CNC machine tools. The method of machining this gear along the contact line has been obtained through the combination of the envelope method and milling principle. Cutter tooth profile equations, coordinate transformation matrices between the non-circular gear tooth surface and orthogonal variable transmission ratio gear tooth surface, transition surface equations and five-axis motion equations were derived. The rolling experiment and tooth surface measurement experiment were conducted on the gear, which was processed by a five-axis CNC machine. The results show that the tooth surface accuracy of the orthogonal variable transmission ratio face gear is high. The design of the orthogonal variable transmission ratio face gear, and its processing method using a five-axis NC machine have been verified.

A five-axis CNC machining method of orthogonal variable transmission ratio face gear

Bending stress analysis of orthogonal curve-face gear

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A five-axis CNC machining method of orthogonal variable transmission ratio face gear

Bending stress analysis of orthogonal curve-face gear