ZK蜗杆磨削中砂轮廓形的智能化修整

提出了包含多个砂轮修整参数的锥面砂轮数学模型，推导出了基于该砂轮模型的ZK蜗杆齿面方程。在此基础上，讨论了数学模型中修整参数对砂轮廓形的影响规律，提出了ZK蜗杆磨削过程中砂轮的智能化修整原理，实现了根据砂轮半径的变化对砂轮廓形进行高精度、实时地自动修整。     

面齿轮蜗杆砂轮的成形修整工艺误差建模及补偿方法

蜗杆砂轮磨削是面齿轮的精加工工艺,蜗杆砂轮修整精度直接影响面齿轮磨削精度。本文分析了修整工艺误差对磨削齿面误差的影响规律,并提出了一种面齿轮蜗杆砂轮的成形修整工艺误差建模及补偿方法。首先,建立面齿轮蜗杆砂轮的数学模型,分析面齿轮蜗杆砂轮的成形修整原理,提出利用圆柱齿轮磨齿机的多轴耦合联动实现面齿轮蜗杆砂轮的成形修整。其次,将修整工艺误差分为轴向位置和径向位置误差,分析轴向位置和径向位置误差对磨削齿面误差的影响规律,提出成形修整工艺误差的补偿方法。最后,进行蜗杆砂轮补偿修整、面齿轮磨削加工及测量实验,实验表明：左齿面齿形误差由补偿前51.9μm到补偿后7.9μm,右齿面齿形误差由补偿前35.3μm到补偿后17.6μm,验证了误差补偿方法的有效性。     

根据齿形公差确定磨削小模数 ZK 蜗杆砂轮直径的研究

本文就砂轮直径的变化对小模数ZK圆柱蜗杆齿形影响问题进行了研究。用计算机对不同头数、不同模数、不同直径的小模数ZK圆柱蜗杆齿形随砂轮直径的变化情况进行了大量的数值计算,从中找出其变化规律,并给出了一个简单实用的小模数ZK圆柱蜗杆齿形误差近似计算公式。利用本文推荐的公式,可根据齿形公差要求,确定出应选砂轮的最大直径和允许的磨损量。     

S7520w手动万能砂轮修整器的调整参数对蜗杆齿形的影响

我国的精密圆柱蜗杆多在配备了手动万能砂轮修整器的螺纹磨床上磨削成形的。这和工艺方法加工出的蜗杆是什么齿形?对此,人们的看法十分不同。有人认为是ZN蜗杆,因为生产图纸上要求ZN;有人认为是ZK蜗杆,因为砂轮近似于盘形锥面砂轮;文献资料普遍认为这种工艺方法加工不出精密的ZN和ZA蜗杆。因此,有必要以S7520w万能螺纹磨床为对象,分析其手动万能砂轮修整器的调整参数对蜗杆齿形的影响。     

蜗杆磨床砂轮修整机构的研究和蜗杆齿形误差的预计

砂轮修整机构是蜗杆磨床的关键部件,它的精度是决定蜗杆齿形误差的重要因素。由于机械制造工业和仪器制造工业的发展,蜗杆精度越来越高,所以各国对于蜗杆磨床砂轮修整机构进行了大量的研究工作,出现了不少专利。各种蜗杆磨床砂轮修整机构的工作原理大致可分为以下数种     

圆柱蜗杆任意截面的齿形计算

文中以ZK型圆柱蜗杆法截面齿形的计算为例来说明圆柱蜗杆任意截面的齿形齿厚计算方法，分析了加工蜗轮的刀具齿形用直线代替的情况和砂轮直径变化对ZK蜗杆齿形的影响。     

砂轮修整工具

国产C8955铲床上的修砂轮工具,其所修整的砂轮,一般只能磨小螺旋角蜗杆,对于大螺旋角蜗杆磨削,存在齿形干涉等问题无法解决,只能手工修整,用样板检查齿形,这样,不仅需技术较熟练的工人,而且质量不易保证。为此,根据英国蜗杆磨床的砂轮修整工具工作原理,制造了一个砂轮修整工其,所修整的砂轮,可对阿基米德蜗杆、齿槽法向直廓蜗杆、齿纹法向     

基于AutoCAD的ZK蜗杆仿真加工

本文基于Active XAutomation技术，利用Visual Basic对AutoCAD进行二次开发，通过布尔运算实现了ZK蜗杆的三维加工仿真，并分析了齿形随砂轮半径变化的规律。     

双导程ZN蜗杆修缘成形磨削研究

双导程ZN蜗杆(又称法向直廓蜗杆)修缘的精密加工需要研究一种成形磨削方法。传统的蜗杆修缘磨削方法是根据加工经验对砂轮进行手工修形,加工效率低且难以实现高精度的齿形修缘磨削。为此,以ZN蜗杆修缘齿形的成形磨削为目标,在蜗杆法平面引入齿形修缘分析,建立ZN蜗杆修缘齿形的数学模型,依据空间啮合原理计算出蜗杆磨削的成形砂轮截形,并利用数控砂轮修整装置修整砂轮。为验证蜗杆修缘的成形磨削效果,选用实际生产中的某一双导程ZN蜗杆,在自主研制的数控砂轮修整系统和工厂的蜗杆磨床上进行试验,经过对成形磨削砂轮计算、修整和蜗杆磨削,结果表明,磨削蜗杆的修缘量满足预期设计要求,蜗杆齿形精度达到6级。表明该方法可用于双导程ZN蜗杆修缘的高精度成形磨削。     

用于磨削面齿轮的蜗杆砂轮修整方法研究

为了实现面齿轮磨齿加工,采用包络原理对面齿轮磨削蜗杆砂轮齿形进行设计,并对蜗杆砂轮的修整方法进行研究.建立了蜗杆砂轮齿面的包络坐标系;给出了蜗杆砂轮产形面方程;推导了蜗杆砂轮齿廓的曲面方程,利用Matlab软件对蜗杆砂轮齿廓进行了仿真,根据面齿轮磨削蜗杆砂轮的齿面生成原理,给出了修整工具的齿廓形状、齿宽限制以及修整工具...     

SELECTION OF GEOMETRIC PARAMETERS OF GEAR AND GRINDING WHEEL TO ENSURE MAXIMUM GEAR TOOTH PROFILE ACCURACY

An analysis of possibilities for the selection of gear and tool geometry parameters is presented to reduce tooth profile errors during the grinding of gears by double tapered wheel (Hofler or Niles method), double wheel generating (Maag method) and by worm wheel techniques (Reishauer method). The selection of gear and tool geometry parameters is based on the analysis of the grid diagram of a gear and a rack. Formulas and graphs are presented for the selection of the pressure angle, module, and addendum of the rack-tool. The experimental results of the grinding of gears confirm the theoretical analysis.     

SELECTION OF GEOMETRIC PARAMETERS OF GEAR AND GRINDING WHEEL TO ENSURE MAXIMUM GEAR TOOTH PROFILE ACCURACY

ABSTRACT

An analysis of possibilities for the selection of gear and tool geometry parameters is presented to reduce tooth profile errors during the grinding of gears by double tapered wheel (Hofler or Niles method), double wheel generating (Maag method) and by worm wheel techniques (Reishauer method). The selection of gear and tool geometry parameters is based on the analysis of the grid diagram of a gear and a rack. Formulas and graphs are presented for the selection of the pressure angle, module, and addendum of the rack-tool. The experimental results of the grinding of gears confirm the theoretical analysis.     

IN SITU TRUING/DRESSING OF DIAMOND WHEEL FOR PRECISION GRINDING

An application for achieving on-machine truing/dressing and monitoring of diamond wheel is dealt with in dry grinding. A dry electrical discharge （ED） assisted truing and dressing method is adopted in preparation of diamond grinding wheels. Effective and precise truing/dressing of a diamond wheel is carried out on a CNC curve grinding machine by utilizing an ED assisted diamond dresser. The dressed wheel is monitored online by a CCD vision system. It detects the topography changes of a wheel surface. The wear condition is evaluated by analyzing the edge deviation of a wheel image. The benefits of the proposed methods are confirmed by the grinding experiments. The designed truing/dressing device has high material removal rate, low dresser wear, and hence guarantees a desired wheel surface. Real-time monitoring of the wheel profile facilitates determining the optimum dressing amount, dressing interval, and the compensation error.     

硬质合金精密滚剃刀齿形制造新技术

给出了用双曲线拟合滚剃刀渐开线蜗杆法剖面齿形新技术，提出了锥面砂轮按斜直线进行修整，能够获得砂轮轴截面为双曲线形状。按此技术修整砂轮，通过对滚剃刀渐形线蜗杆的圆磨，有效地提高了滚剃刀齿形精度。     

A profile dressing method for grinding worm used for helical gear with higher order modification profile

In the case of generation grinding of the higher order modification gear surface, there are main problems such as difficulty in solving the 3D meshing equations and complexity of expressing the profile of grinding worm. In this study, an indirect generating method is proposed to calculate the profile of grinding worm by applying a virtual rack-cutter (VRC) between the grinding worm and the work gear. The grinding worm dressing experiments were processed by using a ball-nose diamond wheel. According to the results of tooth profile deviation measurement, the tooth profile modification curve is coincident with the predesigned modification curve. Compared with the gear without modification, vibration experiments show that the basic frequency, double frequency, and triple frequency decreased simultaneously, which verified the correctness of calculation and effectiveness of dressing for the profile curve of the grinding worm.     

激光与电火花复合修整粗粒度弧形金刚石砂轮试验研究

因受到激光高斯光束特性的影响,辐照在砂轮表面上的光斑大小和激光能量都跟随修整路径变化,难以实现高精度的弧形金刚石砂轮的修整,为此,提出采用激光粗修整和电火花精修整的复合修整方法。先用激光修整高效去除多余磨料层来得到弧形轮廓,再用一高精度弧形电极匹配该轮廓进行电火花修整,得到较高精度的弧形砂轮。在粒度为120的金刚石砂轮上试验修整半径为13 mm的弧形轮廓,最终修整出的弧形轮廓半径为13.006 mm,轮廓误差PV值为10.90 μm。最后,通过磨削氧化铝陶瓷验证了砂轮修整效果。检测磨削工件的弧形轮廓拟合半径为13.012 mm,轮廓误差PV值为11.33 μm。     

大模数硬齿面滚剃刀齿形的近似造型方法

基于硬齿面滚剃刀齿形的制造方法 ,分别采用直线、圆弧、双曲线拟合法对滚剃刀法截面齿形进行了近似造型。近似造型误差计算结果表明 ,直线拟合法误差较大 ,但砂轮修整简单 ;圆弧拟合法误差最小 ,但砂轮修整稍难 ;双曲线拟合法误差很小且砂轮修整简单     

渐开线蜗杆成形磨削用砂轮的修整

成形磨削与车削相比可显著提高蜗杆的齿形精度和表面质量。根据螺旋面形成原理建立了渐开线蜗杆的齿面方程,利用空间啮合理论计算出了磨削蜗杆所需砂轮的轴向截形,依据此截形数据设计了砂轮数控修整方案,并用修整好的砂轮磨削工件实现蜗杆的数控成形磨削加工。