Precision milling method for face-gear by disk cutter

Abstract

In order to accelerate the engineering application of face-gear, a precision milling method for face-gear by disk cutter is provided in this paper. Based on the principle of face-gear drive, the principle of face-gear milling by disk cutter is analyzed, and the mathematical model of the disk cutter is presented according to the meshing principle. Taking the milling needs into account, an innovative machine tool is developed, and the movement control method of face-gear milling by the disk cutter on the special machine tool is provided. For the comparison of tooth surface accuracy, the equation of face-gear tooth surface is calculated, and the 3D model of face-gear is established based on CATIA software. To verify the feasibility of the method, a simulation of face-gear milling is put forward based on VERICUT software. To optimize machining parameters and improve the machining accuracy, an error analysis model of face-gear milling is established, and the corresponding error influence rule caused by installation and movement parameters is obtained. In order to verify the theory, the experiment is carried out, and the completed specimen is detected by coordinate measuring machining (CMM). Finally, the processing parameters are amended according to the detection results and the error influence rule, and the maximum dimensional deviation value of specimen face-gear tooth profile is reduced from 181.2 to 30.4 μm. The result shows that the method of errors amendment can improve processing accuracy, and the generating milling method by disk cutter is an effective approach to achieve the precision face-gear.