Abstract
Classic methods of machining cylindrical gears, such as hobbing or circumferential chiseling, require the use of expensive special machine tools and dedicated tools, which makes production unprofitable, especially in small and medium series. Today, special attention is paid to the technology of making gears using universal CNC (computer numerical control) machine tools with standard cheap tools. On the basis of the presented mathematical model, a software was developed to generate a code that controls a machine tool for machining cylindrical gears with straight and modified tooth line using the multipass method. Made of steel 16MnCr5, gear wheels with a straight tooth line and with a longitudinally modified convex-convex tooth line were machined on a five-axis CNC milling machine DMG MORI CMX50U, using solid carbide milling cutters (cylindrical and ball end) for processing. The manufactured gears were inspected on a ZEISS coordinate measuring machine, using the software Gear Pro Involute. The conformity of the outline, the tooth line, and the gear pitch were assessed. The side surfaces of the teeth after machining according to the planned strategy were also assessed; the tests were carried out using the optical microscope Alicona Infinite Focus G5 and the contact profilographometer Taylor Hobson, Talysurf 120. The presented method is able to provide a very good quality of machined gears in relation to competing methods. The great advantage of this method is the use of a tool that is not geometrically related to the shape of the machined gear profile, which allows the production of cylindrical gears with a tooth and profile line other than the standard.
Highlights
It can be said with certainty that cylindrical gears are still the most frequently used gears
The following parameters of the gear wheel were determined during the measurements: Fα profile deviation, total overlay of profile form deviation and profile slope deviation, ffα form deviation of the profile without consideration of the slope deviation, fHα profile slope deviation of the profile without consideration of the form deviation, Fβ tooth line deviation, total overlay of lead form deviation and lead slope deviation, ffβ form deviation of the lead without consideration of the slope deviation, fHβ lead slope deviation of the outline without consideration of the form deviation, and Cβ modification crowning correction of the helix through convex curvature over the face width measured on the pitch circle
Based on the parameters Fα profile deviation, total overlay of profile form deviation and profile slope deviation, ffα form deviation of the profile without consideration of the slope deviation, and fHα profile slope deviation of the profile without consideration of the form deviation, we can conclude that the obtained profile deviations classify the modified gear wheel with the module m = 3 as accuracy class 7
Summary
It can be said with certainty that cylindrical gears are still the most frequently used gears. They are mainly processed by the hobbing method with modular hob cutters, as well as with Fellows chisels, or a finishing process by grinding according to the Maag, Niles, or Reishauer methods. Involute cylindrical gears with straight teeth are most commonly used in drive units in many machines and devices. They are most often machined using shaping, as presented by Litvin and Fuentes [1]. The study of gear machining with modular disc cutters was presented in the work by Pasternak and Danylchenko [2], who simultaneously analyzed the distribution of cutting forces in the process
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