中凹盘铣刀数控端铣弧齿锥齿轮

为了解决当前数控加工中通用刀具加工弧齿锥齿轮存在的加工效率低、易切削颤振等问题,提出了中凹盘铣刀数控端铣弧齿锥齿轮的方法.基于对弧齿锥齿轮齿面几何结构的研究,通过选择大直径、刀底内凹的盘形铣刀,主动改变刀具姿态角的设置顺序,并分离了前倾角和侧倾角的功能,可以实现弧齿锥齿轮的齿底无干涉和大切削带宽加工.先以切触点位置确定侧倾角避免过切齿槽底面,再以平底刀加工自由曲面的思想分别确定两侧齿面的前倾角,保证大的切削带宽和高加工效率.结果表明:以一个弧齿锥齿轮大轮为例,中凹盘铣刀端铣轮两侧齿面分别以7次、6次切削完成加工,最大加工误差分别为0.039 4mm和0.041 8mm.采用该方法加工弧齿锥齿轮,具有刀具耐用度高,切削带宽大,走刀次数少和加工精度高等优点.

Computer numerical control face milling spiral bevel gears by application of disc cutter with concave end

In order to solve the poor machining efficiency and cutting chatter problem during computer numerical control(CNC) machining of spiral bevel gears by universal cutter, a machining method of face milling spiral bevel gears by a disc cutter with concave end was presented. Based on the research of spiral bevel gears geometry structure, a bigger diameter disc cutter with concave end was selected, and the setting order of cutter orientation angles was changed actively, then the functions of cutter tilt and yaw angle were separated, so the tooth surfaces machined with big cutting strip width and without bottom land gouge could be realized. Through the cutter yaw angle determined by cutting contact point positions in tooth surface machined, the bottom land gouge interference can be avoided effectively. Then through the tilt angles of both side tooth surfaces determined by the theory of sculptured surfaces machined by flat end cutter respectively, big cutting strip width and high machining efficiency can be ensured. The results show that with a spiral bevel gear as an example, the cutting times of two tooth flanks with a disc cutter with concave end are 7 and 6, and the maximum machining errors are 0.0394mm and 0.0418mm, respectively. This method has advantages such as longer cutter life and bigger cutting strip width, fewer cutting times and higher processing precision for machining spiral bevel gears.