MODERN METHODS OF GEAR MILLING OF HARDENED LARGE-MODULE GEARS

Kateryna Kamchatna-Stepanova,Oleksandr Klochko

doi:10.23856/4340

Abstract

The latest developments of modern methods of high-speed gear milling of large-module cylindrical gears, both for preliminary grinding of teeth and for final blade processing of gears, are considered. For high-speed blade gear processing, promising designs of worm carbide cutters have been developed, manufactured and implemented. The technological regulations of blade gear processing for the operation of each of the design solutions of worm carbide cutters have been developed. The design of a special double-body worm cutter for double-sided cutting has been developed. It is shown that the carbide cutting elements of the milling cutters, which are placed only along the lines of the machine engagement of the tool and the workpiece, make it more economical compared to the known designs of similar tools. The application of the developed technological methods of pre-blade processing of the teeth of hardened wheels with carbide cutters reduces the labor intensity of low-performance gear grinding operations, depending on the wheel module, by 3-4 times by reducing the allowance from 1.5–2.5 mm on the tooth side to 0.3–0.5 mm, and also allows you to ensure the gear processing process is economical by reducing the consumption of carbide plates. The developed technological studies of ensuring the quality of gear processing of large-module cylindrical wheels allow us to solve the scientific and technical problem associated with the production of large-module gears with high-hardness teeth while improving the quality of their manufacture, reducing labor costs and reducing material consumption.

Highlights

The increase in production efficiency in various industries is largely due to the development and development of mining and processing equipment, transport and energy systems, and other large-sized machines whose drives include large-module gears (m>12 mm)
The improvement of the specified technological equipment consists in increasing its power, increasing the speed of mutual movement of elements, ensuring the reliability of operation in deteriorating dynamic conditions, increasing durability (Czerniec, M., 2019: 53)
Performing the technological operation of gear grinding on the teeth of a large module in the conditions of removal of an increased allowance (1.0-2.5 mm) leads to the appearance of such defects in the surface layer as «cauterization» and microcracks, and in the layer itself there are tensile stresses, which reduce the load capacity and durability of heavy-loaded cylindrical gears

Summary

Introduction

The increase in production efficiency in various industries is largely due to the development and development of mining and processing equipment, transport and energy systems, and other large-sized machines whose drives include large-module gears (m>12 mm). The scientific novelty of the obtained results is that on the basis of a broad analysis and generalization of industrial achievements in gear processing, requirements for heavy-loaded and responsible gears, general principles for the development of structures and parameters of technological systems for gear processing of hardened large-module gears are formulated and implemented for the first time This allows you to intensify the processing process and increase the efficiency of the process by minimizing the wear rate of the cutting tool and the cost of manufacturing it, provided that high accuracy of engagement and the quality of the surface layer are obtained. The relevance of scientific solutions is to increase the productivity, accuracy and quality of gear processing of hardened large-modular gears on the basis of improving the technological system and kinematics of gear milling, the design of tool and technological equipment This allows you to increase the efficiency of shaping while ensuring the required accuracy of the gears. Experimental studies were conducted using the theory of modeling, discrete and correlation analysis

Technological methods of processing large-module gears

Design features of advanced designs of carbide milling cutters

Findings

Conclusions