Xu Hao, Zhou Yuansheng, He Yuhui, Tang Jinyuan
Changsha Zhongchuan Gear & Transmission Driveline Co., Ltd., Changsha 410200, China.
State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, China.
Materials (Basel). 2021 Aug 26;14(17):4848. doi: 10.3390/ma14174848.
Five-axis flank milling has been applied in industry as a relatively new method to cut spiral bevel gears (SBGs) for its flexibility, especially for the applications of small batches and repairs. However, it still has critical inferior aspects compared to the traditional manufacturing ways of SBGs: the efficiency is low, and the machining accuracy may not ensure the qualified meshing performances. To improve the efficiency, especially for cutting non-ferrous metals, this work proposes an approach to simultaneously cut the tooth surface and tooth bottom by a filleted cutter with only one pass. Meanwhile, the machining accuracy of the contact area is considered beforehand for the tool path optimization to ensure the meshing performances, which is further confirmed by FEM (finite element method). For the convenience of the FEM, the tooth surface points are calculated with an even distribution, and the calculation process is efficiently implemented with a closed-form solution. Based on the proposed method, the number (or total length) of the tool path is reduced, and the contact area is qualified. Both the simulation and cutting experiment are implemented to validate the proposed method.
五轴侧铣作为一种相对较新的方法已在工业中应用于加工螺旋锥齿轮（SBG），因其具有灵活性，尤其适用于小批量生产和维修应用。然而，与传统的螺旋锥齿轮制造方法相比，它仍存在关键的不足之处：效率低，且加工精度可能无法确保合格的啮合性能。为了提高效率，特别是在切削有色金属时，本文提出一种方法，使用带圆角的刀具一次走刀同时切削齿面和齿底。同时，在刀具路径优化时预先考虑接触区域的加工精度以确保啮合性能，这通过有限元方法（FEM）得到进一步验证。为便于进行有限元分析，齿面点采用均匀分布进行计算，且计算过程通过闭式解高效实现。基于所提出的方法，刀具路径的数量（或总长度）减少，且接触区域合格。通过仿真和切削实验对所提出的方法进行了验证。
