Abstract
To solve the problem of low efficiency in digital generating machining for producing small or medium batches of helical gears, a method to improve the machining efficiency with an indexable disk milling cutter is presented in this paper. First, the mathematical model of the tooth profile and the indexable disk milling cutter are established. Second, according to the spatial free-form envelope theory, the overall planning scheme of the tool path is given; the relative position and the relative transformation matrix of the tool and tooth profile during digital generating machining using the indexable disk milling cutter are solved, the simulation cutting and actual cutting experiments are conducted, and the cutting efficiency per unit time and cutting simulation time of the two tools under the same deformation conditions is obtained through a finite element analysis experiment. The results show that the cutting efficiency of the indexable disk milling tool was 2–3 times higher than that of the end mill cutter.
Highlights
Cylindrical gears are widely used for motion and power transmission between parallel shafts and are key basic parts in aviation, automotive, energy, and other fields
With the gradual development of mechanical products in the direction of small-batch customization, the shortcomings of traditional gear processing methods are increasingly prominent. This has led to the emergence of a digital generating method based on the spatial free-form envelope theory, which is realized by multiple-tool flank milling on a general-purpose multi-axis computer numerical control(CNC) machining center
Researchers have extensively worked on digital generating tool path planning and machining accuracy control of gears using end milling cutters, while the research on digital generating machining using disc milling cutters is mostly focused on spiral bevel gear machining; there is a lack of relevant research on digital spreading of cylindrical gears with disc milling cutters
Summary
Cylindrical gears are widely used for motion and power transmission between parallel shafts and are key basic parts in aviation, automotive, energy, and other fields. With the gradual development of mechanical products in the direction of small-batch customization, the shortcomings of traditional gear processing methods (requiring special machine tools and special tools, long processing preparation cycles, and insufficient machine tool start-up rates) are increasingly prominent. This has led to the emergence of a digital generating method based on the spatial free-form envelope theory, which is realized by multiple-tool flank milling on a general-purpose multi-axis computer numerical control(CNC) machining center. Compared to the digital generation of gears with the end milling cutter, this method can improve the material removal rate of the machining gear to a considerable extent while maintaining the quality of tooth surface machining
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