Reduction of power and lubricant oil consumption in milling process using a new SiO2 nanolubrication system

In this paper, we propose a method based on the surfaces enveloping theory developed as a vertical application in the CATIA graphical design environment. This method is created for profiling tools intended to generate cylindrical helical surfaces with constant pitch. The devised method is applicable for the profiling of disc tools which are bounded by a primary peripheral surface of revolution. A few examples for the determination of the tool’s 3D primary peripheral surface are presented such as helical flutes of cutting tools, worms with wide pitches, and gear involute flanks. The results are presented in both graphical and tabular form for completeness. Screen snapshots of the CATIA-based vertical application are also shown.     

A study on helical surface generated by the primary peripheral surfaces of ring tool

Often in the engineering practice, cutting tools bounded by primary peripheral surfaces of revolution are used because of their effectiveness. Among these, ring and tangential tools can be used for the generation of constant pitch cylindrical helical surfaces. In this paper, we present an algorithm for the profiling of these types of tools. The algorithm is based on the topological representation of the tool’s primary peripheral surface. The main goal is to devise a methodology for the profiling of tools whose surfaces are reciprocally enveloping with cylindrical helical surfaces. We present a numerical example for the numerical determination of the axial section form for this type of tools. The application method for this algorithm was developed in the CATIA graphical design environment within which the procedure is developed as a vertical application. In addition, we present a solution for the shape correction of the tool’s axial cross-section by considering the existence of singular points on the profile of the helical surface to be generated where multiple normals to the surface exist.     

锥面二次包络圆柱蜗杆传动蜗轮滚刀的研制

论述了锥面包络蜗轮滚刀的成形原理,推导了锥面包络蜗杆曲面方程,计算了蜗轮滚刀的法向齿形,据此设计制造的锥面包络蜗轮滚刀性能良好。     

圆柱齿轮滚切多刃断续切削空间成形模型及应用

滚切加工作为当前圆柱齿轮制造应用最为广泛的工艺具有高效但成形过程复杂的特点。基于展成原理,由规则分布在滚刀基本蜗杆螺旋面上的一系列切削刃相继从圆柱齿坯上切除材料,最终包络形成渐开线齿面。研究其成形原理可以为提升该工艺性能提供有效指导。针对齿轮滚切工艺过程多刃切削成形特征,建立圆柱齿轮滚切的空间成形模型。基于滚刀几何结构参数的理论约束关系,建立滚刀切削刃序列的参数方程;根据滚刀和工件的几何参数以及切削参数确定滚切过程中滚刀与工件的空间位置和运动关系,并基于空间运动学方法推导求得滚刀刀刃序列形成的空间成形曲面参数模型;采用离散数值方法获得滚切过程中的切屑几何形态及切屑厚度,并根据切屑几何计算各刀刃去除材料时的瞬时主切削力。该模型可以为滚切工艺参数优化、滚刀几何设计等研究提供支撑。     

硬齿面双圆弧齿轮滚刀的齿面方程及二次刀具廓形设计

论述了硬齿面双圆弧齿轮滚刀的结构特点，从双圆弧齿轮滚刀的基本蜗杆齿轮面方程出发，利用啮合原理推导出具有直沟负前角的滚刀的前刀面齿形计算公式和铲齿齿背的曲面方程，再利用齿背曲面和铲磨运动的关系求出铲磨滚刀的砂轮轴向载面廓形，并给出了负前角双圆弧滚刀铲磨砂轮截面的具体算例。     

加工齿轮滚刀齿形过程中如何提高齿形精度

针对阿基米德滚刀加工渐开线圆柱齿轮,用阿基米德造型的滚刀在刃磨滚刀齿形时,为了提高齿形精度,改变加工工艺和检测工艺,使用先进的"砂轮修正器"和"齿轮测量中心",缩短了设计和加工时间,提高了齿轮滚刀齿形磨制的效率,保证了滚刀加工渐开线圆柱齿轮齿形精度,使大于4模数的阿基米德滚刀齿形(A级﹑AA级)易于保证被加工渐开线圆柱齿轮的齿形精度。     

锥面二次包络圆柱蜗杆传动的啮合性能分析

以微分几何与空间啮合理论为基础,推导了锥面二次包络圆柱蜗杆传动两次包络过程中的啮合方程和主要啮合性能指标方程,以图直观的表示出其形状、位置和分布状况。研究发现蜗杆副在砂轮半径一定的变化范围之内,其接触性能和传动啮合性能变化不大,为这类蜗杆传动中蜗轮滚刀的设计制造提供了理论基础。     

磨削TI蜗杆的砂轮廓形

TI蜗杆由渐开线斜齿轮包络形成,与斜齿轮组成一种环面蜗杆传动.TI蜗杆传动推广应用的关键制造技术是解决蜗杆齿面的精确磨削问题,即确定出与磨削方法相对应的砂轮廓形.分析TI蜗杆传动运动关系和TI蜗杆产形面特点,将对TI蜗杆的磨削转化为成形砂轮磨削渐开线螺旋面的问题.依据齿轮啮合理论,推导出砂轮磨削渐开线螺旋面的啮合方程,依此得到精确磨削TI蜗杆的砂轮轴断面廓形.     

Design and simulation of meshing of new type of worm-gear drive with localized contacts

The design and simulation of meshing of a single enveloping worm-gear drive with modified surfaces is presented. Generally worm-gear is generated by the hob which is identical, to the worm. This process guarantees the conjugation between the worm and the gear but results in a line contact at every instant which is very sensitive to misalignment. The localization of bearing contact is necessary to reduce the sensitivity of the worm-gear drive to misalignment. Practically this localization is achieved by application of an oversized worm type hob to cut the worm-gear. The oversized hob approach is very practical and effective to localize bearing contact but can not provide the conjugation between the worm and the modified worm-gear. This work proposes an analytical procedure to make the worm surface conjugate to the worm-gear which is cut by the oversized hob. The developed computer program allows the investigation of the influence of misalignment on the shift of the bearing contact and the determination of the transmission errors, the contact ratio and the principle curvatures. The developed approach has been applied for ZK type of single-enveloping worm-gear drives and the developed theory is illustrated with a numerical example.     

Computation of helical or spur gear fillets

This paper presents an algorithm for computing the form of helical or spur gear fillets on a digital computer. These types of tools are considered to generate the fillet: rack-type tool (hob, rack cutter, or grinding wheel) with or without a protruberance, shaper cutter, and shaving tool. Formulae for the coordinates of the fillet are derived and the boundary points of the fillet are determined both for non-undercut and undercut gearing. Flow diagrams for the solution of some difficult problems are given.     

齿轮滚刀齿形造形理论及设计方法的探讨

分析了现行齿轮滚刀齿形造形理论及近似设计方法引起的滚刀齿形精度问题 ,提出一种齿轮滚刀齿形设计新方案———多参数优化齿形设计方法。采用该方法可在显著减小造形误差的同时保证刀齿的精度寿命。     

空间螺旋啮合中啮合点和接触点三维坐标的计算新法及其应用

空间螺旋啮合问题现时有几种简化解法,但似乎都没有从根本上得到简化。本文以辅助齿条为媒介,利用螺旋与齿条可以啮合,并在端平面上有平面啮合关系,先求出啮合点（x p,y p,z p）中的x p,y p;再利用螺旋和斜齿条有法向啮合关系求出z p,而三者之间有十列简单的关系式：z p＝x p tanβ 1＝-y p tanγtanβ 1＝h 1λ 1（1）-x p=y p tanγ（2）式中γ——与齿轮啮合的辅助齿条端面齿廓的切线角;β 1——斜齿轮1的螺旋角;h 1——斜齿轮1的螺旋参数;λ 1——斜齿轮1的螺旋转角。当工件为直齿时,β 1=0,z p=0,这个问题就蜕化为平面啮合问题。当工件为斜齿时,则须求出z p和λ 1。文中详细证明了公式（1）及（2）的正确性,并以螺旋滚刀设计为例,利用空间坐标变换和螺旋运动,把它应用到解空间螺旋啮合问题中去,得到非常简单的结果,并已在实际应用中得到验证。当然本文主要为解工件为斜齿轮的滚刀齿廓如摆线螺杆泵滚刀。应当说明空虚问题比较复杂。如Ю.В,ЦЗИC[7]在求螺旋矩形花键滚刀齿廓时,为了简化解法,误把z p=0,结果把空间螺旋啮合问题当做平面啮合问题解了,得出错误的结果。本文同时解决了空间啮合迹线和齿条齿面上接触点以及接触线的计算方法。     

螺旋渐开线齿轮的齿面生成研究

针对圆柱型螺旋渐开线齿轮不易滚削加工的问题,构造出一种碟形螺旋渐开线齿轮,使其滚削加工成为可能。根据齿轮啮合原理及特殊的加工方法,由产形齿条的齿面方程,推导了碟形螺旋渐开线齿轮的渐开螺旋面、过渡曲面及齿根面的方程。采用MATLAB编程得到碟形螺旋渐开线齿轮齿面的点三维坐标值。由生成的齿面上点的三维坐标值,在Pro/E中构建了碟形螺旋渐开线齿轮精确实体模型,为该齿轮的接触分析与有限元分析奠定了基础。     

螺旋渐开线齿轮的齿面生成研究

针对圆柱型螺旋渐开线齿轮不易滚削加工的问题,构造出一种碟形螺旋渐开线齿轮,使其滚削加工成为可能。根据齿轮啮合原理及特殊的加工方法,由产形齿条的齿面方程,推导了碟形螺旋渐开线齿轮的渐开螺旋面、过渡曲面及齿根面的方程。采用MATLAB编程得到碟形螺旋渐开线齿轮齿面的点三维坐标值。由生成的齿面上点的三维坐标值,在Pro/E中构建了碟形螺旋渐开线齿轮精确实体模型,为该齿轮的接触分析与有限元分析奠定了基础。     

重磨螺旋槽滚刀时砂轮修形自动编程系统的开发

磨削螺旋槽滚刀前刃面时,为获得砂轮母线需要通过调整靠模圆柱的角度,反复试切,影响了生产效率。针对该问题本文以VC++为开发工具,根据开刃磨过程中刀具前刃面的成形原理,建立了计算砂轮理论廓形的数学模型,精准地计算出砂轮的廓形,实现了数控开刃磨砂轮廓形数控加工NC代码的自动编程。     

斜齿面齿轮蜗杆砂轮磨削的双参数法

针对面齿轮硬齿面磨削加工中存在的困难,提出用蜗杆砂轮磨削的双参数法来磨削面齿轮。借助一个渐开线斜齿圆柱齿轮的刀具齿面推导出蜗杆砂轮齿面,由蜗杆砂轮齿面经双参数包络生成斜齿面齿轮齿面。确定了刀具轴与蜗杆砂轮轴夹角大小,分析了双参数包络的形成及包络过程,并用计算机形成了可视化结果,获得了理想的面齿轮齿面。     

微小型齿轮的微细滚削加工研究

用自行设计的微小型硬质合金齿轮滚刀进行了模数为0.175mm的微小型齿轮滚削加工研究.首先设计了相应模数的微小型齿轮滚刀,并详细阐述该刀具的设计过程,包括刀具材料的选择、结构形式的设计、齿形设计和刀具局部强度的校核等.简述了该滚刀的制造加工工艺,在微小型数控滚齿机上进行了微小型齿轮的滚削加工试验研究.结果表明,采用范成...     

线面共轭啮合原理及齿面构建方法

定义曲线与曲面共轭啮合的概念,即给定运动的两构件上的一条光滑曲线和一个光滑曲面始终保持连续相切接触,并给出由共轭啮合副齿面形成曲线与曲面共轭啮合的一般方法,在共轭啮合副的一个齿面上构建啮合管齿面与另一齿面相啮和;提出以适当半径的球体沿啮合曲线的指定等距线包络出管状曲面的齿面构建新方法,推导啮合管齿面方程、接触曲线方程等,给出啮合曲线选取的条件以及啮合管齿面半径的选取范围,从而建立以啮合曲线为脊线构建管状共轭齿面的理论;以摆线针轮行星传动为例,构建针齿螺旋管齿面,讨论线面共轭摆线针轮行星传动的特性;分析表明,线面共轭具有点接触特性,通过构建合适的线面共轭啮合副,可获得近似纯滚动啮合,齿面滑动率小,传动效率高。     

Geometrical aspects of double enveloping worm gear drive

Double enveloping worm gearing is expected to have contact over larger number of teeth and higher load carrying capacity compared to single enveloping worm gearing. In this paper, contact in this gearing is analysed by geometrical simulation of worm gear tooth generation using intersection profiles of different axial sections of worm representing the hob tooth profile with transverse plane of worm gear. The analysis reveals that in the engaging zone a straight line contact always exists in the median plane and intermittent contact exists at the extreme end sections of worm. This has lead to the idea of using two fly cutters positioned at the location identical to the extreme end sections of worm to generate full worm gear tooth thereby eliminating the need for hobs of complex geometry. For a given worm, a mating worm gear is machined in a gear hobbing machine using fly tool in two settings and nature of contact with the worm is checked by a blue test.