【作者】 张婧；

【导师】 王太勇；

【作者基本信息】 天津大学 ， 机械制造及其自动化， 2012， 博士

【摘要】 螺旋锥齿轮代表了目前最复杂的传动形式和高复杂度的曲面加工类型，由于其重合度高、传动平稳、噪声小、承载能力大、传动比大等优点，被广泛应用于汽车、工程机械、航空航天、船舶等领域。而齿面接触区的形状、大小和位置，对齿轮的平稳运转、使用寿命和噪音具有直接影响。所以，齿面接触区是衡量锥齿轮啮合质量的重要标志之一。本文以Gleason的收缩齿制准双曲面齿轮为研究对象，从改善齿面接触情况、提高生产效率及研究四轴数控机床加工技术的本质出发，以微分几何和齿轮啮合原理为理论基础，采用计算机仿真为方法和手段，对螺旋锥齿轮成形理论及方法进行了深入的研究，并建立了螺旋锥齿轮数控成形仿真系统。论文的主要成果及创新点如下：1、基于平面产形轮原理，提出新的螺旋锥齿轮成形理论及加工方法，即螺旋变性半展成法。通过对新加工方法的研究，实现更多自由度的齿面误差修正能力，从本质上避免理论接触区对角现象；完善并增强多轴联动数控铣齿机加工螺旋锥齿轮的能力。2、将小轮刀盘切削刃形成的曲面看作是阿基米德螺旋面，用以替代小轮精切锥面刀盘的螺旋运动。工件与产形轮仍然按照一定的传动比绕各自的轴线旋转，曲率计算时可以直接利用准双曲面齿轮副在节点处的曲率关系，简化了切齿计算过程。3、针对国产四轴联动数控铣齿机，提出螺旋锥齿轮“两刀法”加工理论。基于新的螺旋锥齿轮成形理论及加工方法，通过对多轴联动数控铣齿机各轴的灵活有效控制，实现使用双面刀盘精切小轮凹、凸面，提高多轴联动数控机床加工柔性、生产效率和加工精度，实现加工的低成本、高效率、高质量。4、在理论研究基础上，推导了四轴联动数控铣齿机螺旋锥齿轮成形运动关系，建立了螺旋锥齿轮的数控加工模型，给出了机床运动与调整的全部运动关系。简化了数字化制造环境下螺旋锥齿轮少轴加工工艺过程，并取得了良好接触区。5、提出了螺旋锥齿轮切削仿真方法，在此基础上实现了刀具和齿坯的布尔运算，实现了所得齿面数据点的存储和重构、切削过程的实时显示，开发出了螺旋锥齿轮数控成形仿真系统。更多还原

【Abstract】 The most complicated transmission forms and the high complexity in curvedsurface machining types were represented by hypoid gears. Hypoid gears were widelyapplied in automobile, engineering machinery, Aerospace, shipping industry, becausethat hypoid gears had the advantages that high contact ratio, steady transmission,lower noise, large loading capacity, large transmission ratio. The form, size andlocation of tooth flanks contact zone directly affected the stable running, working lifeand noise of hypoid gear drives. The tooth flanks contact zones was one of theimportant symbols to examine the meshing quality of the hypoid gear pairs. Thereductive tooth system of Gleason hypoid gears was the research objects of this paper.The theory and method of the machining technology about hypoid gears wasresearched by the paper, in improving production efficiency, in improving the form oftooth surface contact zone, and in studying the essence of the machining technologyin four axis NC machine tool. The research was based on differential geometry andthe principle of gear engagement. The computer simulation was the method andmeans of the research.The main results and innovations of this paper is listed as follows:1. The half-spread-out helix modified roll method based on crown generatinggear principle was proposed, which was the machining method of hypoid gears basedon the new forming theory. The new machining theory was founded. The toothsurface corrections in more degrees of freedom was achieved by study in the newmachining method. The Bias of tooth contact zone was prevented in essence. Thehypoid gears processing capacity of multi-axes synchronous CNC gear millingmachine was improved.2. The surface which was formed by the cutting edge of cutter for pinion wasregarded as the Archimedes spiral curved surface. It was substituted for the helicalmotion of the cone segmental-blade cutter for pinion. The work-piece and the crowngenerating gear revolved around their axes according certain transmission ratio. Thecurvature rate at nodes of hypoid gear pair could be used directly in curvatureestimation. The process of calculation for cutting was simplified.3. The “Two Cut” machining theory was proposed, aiming at domestic four-axessynchronous CNC gear milling machine. It was implemented that the alternate bladecutter was used to finish cutting the tooth surfaces of pinion, by flexible and effective controlling the movement axes of the multi-axes synchronous CNC machine, basedon the new forming theory and the new machining method of hypoid gears. Thatimproved the flexible manufacturing, production efficiency and machining precisionof multi-axes synchronous CNC machine. The machining processing of low-cost,high-efficiency, and high-quality was implemented.4. On the base of theoretical research, the motion relationship of the four-axessynchronous CNC gear milling machine, which was used to machine hypoid gears,was deduced. The NC machining model of hypoid gears was established. All of themotion relationship in motion and settings of machine tool were provided. Themachining process of hypoid gears in four-axes digital manufacturing was simplified,and the form of tooth contact zone was satisfied.5. The machining simulation method of hypoid gears was proposed, which theBoolean operation of the cutter with work piece was implemented based on. The datapoints of the tooth surface was stored and reconstructed. The real-time display ofmachining process was implemented. The machining simulation system of hypoidgears was developed.更多还原