CN115091150B - Rapid trial-manufacturing processing method of high-precision transmission gear and transmission gear - Google Patents
Rapid trial-manufacturing processing method of high-precision transmission gear and transmission gear Download PDFInfo
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- CN115091150B CN115091150B CN202210726114.9A CN202210726114A CN115091150B CN 115091150 B CN115091150 B CN 115091150B CN 202210726114 A CN202210726114 A CN 202210726114A CN 115091150 B CN115091150 B CN 115091150B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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Abstract
The technical scheme of the invention provides a rapid trial-manufacturing method of a high-precision transmission gear and the transmission gear manufactured by the method, wherein a soft claw chuck is used for clamping a gear bar for rough machining and finish machining to obtain a gear blank during machining, and a soft claw chuck machining mode, a soft claw chuck clamping position and a bar machining surface size matched with the gear bar are selected according to the workpiece size, so that the rapid trial-manufacturing method of the gear suitable for small-batch gear production is provided, and the gear manufactured by the method can meet the high-precision requirement of the transmission gear of an automobile.
Description
Technical Field
The invention belongs to the field of processing of speed changer gears, and particularly relates to a rapid trial-manufacturing processing method of a high-precision speed changer gear and the speed changer gear manufactured by the processing method.
Background
With the improvement of living standard, the automobile industry tends to widen the functions of vehicles and pursue diversification of use scenes, so that new requirements are put on an automobile gearbox, and a gear is used as one of important transmission mechanisms of the gearbox, so that the gear is required to have structural dimensional accuracy and material strength enough to bear complex working conditions such as high rotating speed, high load and the like. For example, the positioning reference precision requirement of the double-clutch transmission with a complex structure on the inner hole of the gear is within 0.015mm, so that the running abrasion of the gear is slowed down, the service lives of the gear and the transmission are prolonged, and the noise and vibration of the whole vehicle are reduced.
The existing transmission gear is generally processed by adopting special equipment and a special fixture, has high processing cost and long production period, is not suitable for small-batch processing production, and is lack of a rapid trial processing method which can ensure the processing precision of the transmission gear and is suitable for small-batch gear production.
Disclosure of Invention
In order to overcome the defects in the background art, the technical scheme of the invention provides a rapid trial-manufacturing processing method of a high-precision transmission gear, which comprises the following steps:
s1, clamping a gear bar by using a soft jaw chuck, and performing rough machining and finish machining to obtain a gear blank;
s2, hobbing;
s3, heat treatment;
s4, grinding;
s5, carrying out finish machining on the surface of the semi-finished gear subjected to heat treatment by using a forming gear grinding machine to obtain a transmission gear with more than six stages of precision;
wherein, the rough machining in the step S1 comprises the following steps:
s11, the gear bar material penetrates into the soft jaw chuck with a first preset length and is clamped by the soft jaw chuck to form an excircle of the bar material, and a first end face of the bar material protrudes outwards from the chuck;
s12, turning an inner hole of a gear, a first end face of a gear bar and an outer circle of the bar, wherein a machined surface of the outer circle of the bar extends from the first end face of the bar to the second end face of the bar for a second preset length, the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar, and in the S12 step, the coaxiality of the first end face and the inner hole is controlled to be smaller than or equal to 0.01mm, and the roughness of a gear workpiece of a transmission is controlled to be not larger than Ra1.6;
the finishing in step S1 comprises the steps of:
s13, machining the inner side of the soft jaw chuck, so that the soft jaw chuck stably clamps the outer circle diameter of the workpiece subjected to turning in the S12 in an arc shape;
s14, clamping the gear bar by the surface adjusting device, turning the gear bar into a soft jaw chuck with a third preset length, machining the second end face, controlling the second preset length to be larger than the third preset length, controlling the runout of the soft jaw chuck to be smaller than or equal to 0.01mm, controlling the perpendicularity of an inner hole of the chuck and the end face of the chuck to be smaller than or equal to 0.005mm, and controlling the roughness of the gear workpiece of the transmission to be not larger than Ra1.6.
Further, before executing step S5, the precision of the clamp is adjusted to be within 0.003mm, the inner hole is expanded through the expansion sleeve, and then the center is used for propping up the expansion sleeve, and the second end face is used as a positioning face for grinding teeth.
Further, step S5 includes the steps of:
s51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feeding amount ratio of the dressing wheel when the grinding wheel rotates once;
s52, performing rough grinding and fine grinding on the surface of the semi-finished gear by using the trimmed grinding wheel.
Further, at the time of performing the rough grinding process, the linear velocity ratio was configured to be 0.8, and the feed amount ratio was configured to be 6; when the fine grinding process is performed, the linear velocity ratio is configured to be-0.8 and the feed amount ratio is configured to be 10.
Further, in executing step S5, the tooth form inclination deviation is controlled to be within 5 levels, the tooth direction helix angle deviation is controlled to be within 6 levels, the accumulated deviation of the peripheral knots is not more than 4 levels, and the tooth form drum shape is less than 0.008mm.
The invention also provides a high-precision transmission gear which is manufactured by adopting the rapid trial-manufacturing processing method of the high-precision transmission gear.
The technical scheme of the invention provides a rapid trial-manufacturing method of a high-precision transmission gear and the transmission gear manufactured by the method, wherein a soft claw chuck is used for clamping a gear bar for rough machining and finish machining to obtain a gear blank during machining, and a soft claw chuck machining mode, a soft claw chuck clamping position and a bar machining surface size matched with the gear bar are selected according to the workpiece size, so that the rapid trial-manufacturing method of the gear suitable for small-batch gear production is provided, and the gear manufactured by the method can meet the high-precision requirement of the transmission gear of an automobile.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below.
FIG. 1 is a flow chart of a method of rapid prototyping of a high-precision transmission gear;
FIG. 2 is a schematic illustration of one of the processing configurations for clamping a gear bar using a soft jaw chuck;
FIG. 3 is a second schematic view of a processing configuration for clamping a gear bar using a soft jaw chuck;
fig. 4 is a schematic diagram of a gear machining structure for gear grinding by using a tip to tightly press an expansion sleeve.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Before discussing exemplary embodiments in more detail, it should be mentioned that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although a flowchart depicts operations as a sequential process, many of the operations can be performed in parallel, concurrently, or at the same time. Furthermore, the order of the operations may be rearranged. The process may be terminated when its operations are completed, but may have additional steps not included in the figures. The processes may correspond to methods, functions, procedures, subroutines, and the like.
Specific structural and functional details disclosed herein are merely representative and are for purposes of describing exemplary embodiments of the invention. The invention may be embodied in many alternate forms and should not be construed as limited to only the embodiments set forth herein.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
With the improvement of living standard, the automobile industry tends to widen the functions of vehicles and pursue diversification of use scenes, and consumers expect that the automobiles not only have the shock resistance of off-road vehicles, but also have the silence and comfort of sedans, so that new requirements are put on the automobile gearbox, particularly, the requirements on the carrying capacity, the shock resistance, the noise performance and the like of gears which are one of important transmission mechanisms of the gearbox are also higher and higher, and the requirements on the structural dimensional accuracy and the material strength of the automobile are enough to bear complex working conditions such as high rotating speed, high load and the like.
For example, the gearbox of the dual clutch transmission with a complex structure consists of a plurality of gears and an input shaft, and the positioning reference precision of the inner hole is required to be within 0.015mm due to high assembly precision, because long-time high-speed and strong-load operation directly affects the service life of the transmission, the higher the gear precision is, the smoother the gear precision is when the gear is meshed with other gears, the gear impact is reduced, the running abrasion of the gears is slowed down, the service lives of the gears and the transmission are prolonged, and the noise and vibration of the whole vehicle are reduced.
The existing transmission gear is generally processed by adopting special equipment and a special fixture, has high processing cost and long production period, is not suitable for small-batch processing production, and is lack of a rapid trial processing method which can ensure the processing precision of the transmission gear and is suitable for small-batch gear production.
In order to overcome the defects, the technical scheme of the invention provides a rapid trial-manufacturing method of a high-precision transmission gear and the transmission gear manufactured by the method, wherein a soft jaw chuck is used for clamping a gear bar for rough machining and finish machining to obtain a gear blank during machining, and a soft jaw chuck machining mode, a soft jaw chuck clamping position and a bar machining surface size matched with the gear bar are selected according to the workpiece size, so that the rapid trial-manufacturing method of the gear suitable for small-batch gear production is provided, and the gear manufactured by the method can meet the high-precision requirement of the automobile transmission gear.
The technical scheme of the invention is further described in detail below with reference to fig. 1-4 and specific examples.
In the first embodiment of the invention:
the technical scheme of the invention provides a rapid trial-manufacture processing method of a high-precision transmission gear, which is shown in figures 1-4, and comprises the following steps:
step S1, the gear 2 bar is clamped by the soft jaw chuck 1 to be subjected to rough machining and finish machining to obtain a gear blank, the gear 2 bar can be flexibly selected, special equipment and furniture are not required to be customized according to the size of the bar, and the gear blank is beneficial to improving production efficiency, shortening production period and reducing production cost.
Specifically, the rough machining in step S1 includes the steps of:
s11, the gear 2 is penetrated into the soft jaw chuck by a first preset length, the outer circle of the bar is clamped by the soft jaw chuck, and the first end face 3 of the bar protrudes to the outer side of the chuck.
Introducing a soft jaw chuck and clamping an excircle of a gear bar to be processed by using the soft jaw chuck, wherein one end part of the gear bar penetrates into the soft jaw chuck by a first preset length and is stably clamped by the soft jaw chuck, the end face of the end part is defined as a second end face, the end face of the other end part is defined as a first end face, the first end face protrudes outwards relative to the chuck, and the gear bar is subjected to a subsequent processing procedure.
S12, turning the gear inner hole 4, the first end face 3 of the gear bar and the outer circle of the bar, wherein the machined surface of the outer circle of the bar extends from the first end face 3 of the bar to the second end face 5 by a second preset length, and the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar.
The gear rod is fixed by using the soft jaw chuck, all elements of the gear inner hole 4, the first end face 3 of the gear rod and the outer circle structure of the rod are machined, wherein the length of a gear machining face of the outer circle structure of the rod is preset, the machining face of the outer circle of the rod extends from the first end face 3 of the rod to the second end face 5 by a second preset length, the sum of the first preset length and the second preset length is controlled to be smaller than the width of the rod, the turning space for rough machining of the first end face is reserved, interference with the soft jaw chuck is avoided when the second end face is machined by adjusting the face, and the machining precision of the gear is controlled to meet the precision requirement of a gear of a vehicle transmission.
Optionally, step S12 is performed, where the transmission gear workpiece roughness is not greater than ra1.6, to ensure that when S12 uses the soft jaw chuck to process the first end face of the bar, the processing precision of the tooth blank meets the precision requirement of the transmission gear of the automobile, and to provide a high-precision tooth blank as a subsequent processing basis.
Step S1, after the rough machining step, a gear blank of the face-adjusting transmission is clamped by using a soft jaw chuck 1, and a finish machining process is carried out on a second end face of the gear blank, wherein the finish machining process comprises the following steps:
s13, machining the inner side of the soft jaw chuck 1, and enabling the soft jaw chuck to stably clamp the outer circle of the workpiece subjected to turning in the S12 in an arc shape.
And according to the diameter of the excircle of the tooth blank workpiece, turning the inner side of a soft jaw chuck to be an arc matched with the diameter of the excircle of the tooth blank workpiece, and stably clamping the excircle of the workpiece subjected to S12 turning treatment by the soft jaw chuck for subsequent processing procedures.
S14, clamping the gear bar by the surface adjusting device, enabling the gear bar to penetrate into the soft jaw chuck with a third preset length, turning the second end face 5, and controlling the second preset length to be larger than the third preset length.
The gear bar is clamped by the surface adjusting clamp, the second end surface 5 of the bar protrudes outwards relative to the soft jaw chuck 1, turning is carried out on the second end surface, in the process, the gear bar is kept deep into the turned soft jaw chuck by a third preset length and is stably clamped by the soft jaw chuck to form an outer circle, the third preset length is controlled to be smaller than the second preset length, interference of the soft jaw chuck during turning is avoided, and therefore machining precision of the gear is controlled to meet the precision requirement of a gear of a vehicle transmission.
Optionally, in step S14, the workpiece roughness of the transmission gear is controlled to be not greater than ra1.6, so as to ensure that when the first end surface of the bar is machined by using the soft jaw chuck in S12, the machining precision of the tooth blank meets the precision requirement of the transmission gear of the automobile, and the high-precision tooth blank is provided as a subsequent machining basis.
Optionally, in executing step S14, the runout of the soft jaw chuck is controlled to be less than or equal to 0.01mm, and the verticality between the inner hole of the chuck and the end face of the chuck is controlled to be less than or equal to 0.005mm, so as to ensure that the precision of the tooth blank obtained by using the improved soft jaw chuck to clamp the tooth blank and turning the tooth blank in step S14 meets the requirement of the automobile transmission gear.
And S2, hobbing the gear surface by using a hobbing machine.
Optionally, in executing step S2, the coaxiality of the first end surface of the tooth blank and the inner hole of the tooth blank is controlled to be less than or equal to 0.01mm, so as to ensure that the gear machining precision meets the gear precision requirement of the automobile transmission, and avoid bad engagement and gear impact during the gear operation.
And S3, heat treatment.
Alternatively, the gear heat treatment is often performed by quenching, considering that the transmission gear requires higher strength to withstand high load operating conditions.
And S4, grinding.
Optionally, in the step S4, the inner hole and the inner hole end face are used for positioning and processing the heat-treated tooth blank by using an inner cone and outer cone combined grinding machine, the roundness of the inner hole of the processed tooth blank is controlled to be within 0.005, the cylindricity is controlled to be within 0.01, the perpendicularity of the second end face and the inner hole is controlled to be within 0.005, and the gear precision after grinding processing can reach more than six stages, so that the gear can meet the precision requirement of the gear processing of the automobile transmission.
And S5, machining the surface of the semi-finished gear subjected to heat treatment by using a forming gear grinding machine to obtain the transmission gear with more than six stages of precision. And (3) processing the surface of the semi-finished gear after heat treatment by adopting a forming gear grinding machine, wherein the gear grinding is used as the last procedure of gear hard tooth surface processing so as to correct errors before gear grinding and obtain high gear precision.
Optionally, before machining by using a gear grinding machine, the shape of the grinding wheel is trimmed by controlling the trimming wheel so as to generate a certain amount of distortion in the grinding process to reduce the natural distortion of the gear, and the machining precision of the gear is improved, for example, in the grinding wheel trimming strategy, the trimming of a pressure angle can be performed along the axial direction of the grinding wheel, and a certain amount of distortion is generated in the grinding process through the pressure angle change of the grinding wheel, so that the distortion is superimposed on the natural distortion, the compensation of the distortion is realized, and the tooth profile parameter of the trimmed grinding wheel along the axial direction and the trimming amount of the gear along the tooth width direction maintain a strict corresponding relation.
Specifically, step S5 includes the steps of:
s51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feeding amount ratio of the dressing wheel when the grinding wheel rotates once.
S52, performing rough grinding and fine grinding on the surface of the semi-finished gear by using the trimmed grinding wheel.
When the linear speed direction of the dressing wheel is the same as that of the grinding wheel, the distance between the protruding high points (wave crests) and the recessed low points (wave troughs) on the surface of the grinding wheel after dressing is the largest, the surface of the grinding wheel is sharper, the grinding efficiency is high, and the grinding wheel is suitable for rough grinding. Alternatively, when the rough grinding process is performed, the linear velocity ratio is configured to be 0.8 to improve the gear rough grinding process efficiency and shorten the rough grinding process time.
When the linear speed direction of the dressing wheel is opposite to that of the grinding wheel, the distance between the protruding high points (wave crests) and the recessed low points (wave troughs) on the surface of the grinding wheel after dressing is small, which indicates that the surface of the grinding wheel is smoother and more flush, which is beneficial to improving the roughness of the tooth surface when grinding a workpiece, but has low grinding efficiency and is suitable for finish grinding. Optionally, the linear speed ratio is configured to-0.8 when performing the lapping process to improve the gear lapping effect and ensure accuracy compliance with the transmission gear accuracy requirements.
Further, the dressing degree of the dressing wheel by the dressing wheel can be controlled by controlling the feed amount ratio of the dressing wheel per one revolution of the grinding wheel to match the requirement of the tooth grinding process, alternatively, the feed amount ratio of the dressing wheel per one revolution of the grinding wheel is configured to be 6 when the rough grinding process is performed using the tooth grinder; in performing the finish grinding process, the feed amount ratio of the dresser disk per one revolution of the grinding wheel is configured to be 10.
Optionally, in order to improve the grinding accuracy, before executing step S5, the fixture accuracy is adjusted to be within 0.003mm, and after the inner hole is expanded by the expansion sleeve 6, the tip 7 is used to jack the expansion sleeve, and the second end face is used as a positioning face for grinding.
Optionally, in executing step S5, the tooth form inclination deviation is controlled within 5 levels, the tooth direction helix angle deviation is controlled within 6 levels, the accumulated deviation of the peripheral knots is not more than 4 levels, and the tooth form drum shape is less than 0.008mm, so as to ensure that the gear processed in step S5 meets the precision requirement of the transmission gear.
In the second embodiment of the invention:
on the basis of the first embodiment, the present embodiment provides a processing method for performing rough machining and finish machining to obtain a tooth blank by clamping a gear bar by using a soft jaw chuck, including the following steps:
and (3) customizing a cylindrical steel material with the length of 40mm and the diameter of 90mm, clamping the excircle of the bar by using a soft jaw chuck, clamping the gear bar by penetrating into the 10mm position of the soft jaw chuck, and projecting the first end of the bar towards the outer side of the chuck.
Turning the gear inner hole, the first end surface of the gear bar and the outer circle of the bar, wherein the machining surface of the outer circle of the bar is 29mm from the first end surface to the second end surface of the bar, the coaxiality of the first end surface and the inner hole is not more than 0.01mm, the surface roughness is not more than Ra1.6, and the diameter of the inner hole is 43mm.
The inner side of the soft jaw chuck is arc-shaped, the diameter of an inner hole of the soft jaw chuck is 85mm, stable clamping can be formed on a gear bar, the soft jaw chuck is controlled to jump by not more than 0.01mm, the roughness is not more than Ra1.6, and the perpendicularity of the inner hole of the chuck and the end face of the chuck is not more than 0.005mm.
And (3) adjusting and clamping the gear bar, enabling the gear bar to extend into the soft jaw chuck by 18mm, enabling the second end face to protrude relative to the soft jaw chuck, and turning the second end face.
The third embodiment of the invention:
the embodiment of the invention provides a high-precision transmission gear, which is manufactured by adopting a rapid trial-manufacturing processing method of the high-precision transmission gear, wherein the rapid trial-manufacturing processing method and the structure of the high-precision transmission gear are shown in figures 1-4, and the method comprises the following steps:
step S1, the gear 2 bar is clamped by the soft jaw chuck 1 to be subjected to rough machining and finish machining to obtain a gear blank, the gear 2 bar can be flexibly selected, special equipment and furniture are not required to be customized according to the size of the bar, and the gear blank is beneficial to improving production efficiency, shortening production period and reducing production cost.
Specifically, the rough machining in step S1 includes the steps of:
s11, the gear 2 is penetrated into the soft jaw chuck by a first preset length, the outer circle of the bar is clamped by the soft jaw chuck, and the first end face 3 of the bar protrudes to the outer side of the chuck.
Introducing a soft jaw chuck and clamping an excircle of a gear bar to be processed by using the soft jaw chuck, wherein one end part of the gear bar penetrates into the soft jaw chuck by a first preset length and is stably clamped by the soft jaw chuck, the end face of the end part is defined as a second end face, the end face of the other end part is defined as a first end face, the first end face protrudes outwards relative to the chuck, and the gear bar is subjected to a subsequent processing procedure.
S12, turning the gear inner hole 4, the first end face 3 of the gear bar and the outer circle of the bar, wherein the machined surface of the outer circle of the bar extends from the first end face 3 of the bar to the second end face 5 by a second preset length, and the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar.
The gear rod is fixed by using the soft jaw chuck, all elements of the gear inner hole 4, the first end face 3 of the gear rod and the outer circle structure of the rod are machined, wherein the length of a gear machining face of the outer circle structure of the rod is preset, the machining face of the outer circle of the rod extends from the first end face 3 of the rod to the second end face 5 by a second preset length, the sum of the first preset length and the second preset length is controlled to be smaller than the width of the rod, the turning space for rough machining of the first end face is reserved, interference with the soft jaw chuck is avoided when the second end face is machined by adjusting the face, and the machining precision of the gear is controlled to meet the precision requirement of a gear of a vehicle transmission.
Optionally, step S12 is performed, where the transmission gear workpiece roughness is not greater than ra1.6, to ensure that when S12 uses the soft jaw chuck to process the first end face of the bar, the processing precision of the tooth blank meets the precision requirement of the transmission gear of the automobile, and to provide a high-precision tooth blank as a subsequent processing basis.
Step S1, after the rough machining step, a gear blank of the face-adjusting transmission is clamped by using a soft jaw chuck 1, and a finish machining process is carried out on a second end face of the gear blank, wherein the finish machining process comprises the following steps:
s13, machining the inner side of the soft jaw chuck 1, and enabling the soft jaw chuck to stably clamp the outer circle of the workpiece subjected to turning in the S12 in an arc shape.
And according to the diameter of the excircle of the tooth blank workpiece, turning the inner side of a soft jaw chuck to be an arc matched with the diameter of the excircle of the tooth blank workpiece, and stably clamping the excircle of the workpiece subjected to S12 turning treatment by the soft jaw chuck for subsequent processing procedures.
S14, clamping the gear bar by the surface adjusting device, enabling the gear bar to penetrate into the soft jaw chuck with a third preset length, turning the second end face 5, and controlling the second preset length to be larger than the third preset length.
The gear bar is clamped by the surface adjusting clamp, the second end surface 5 of the bar protrudes outwards relative to the soft jaw chuck 1, turning is carried out on the second end surface, in the process, the gear bar is kept deep into the turned soft jaw chuck by a third preset length and is stably clamped by the soft jaw chuck to form an outer circle, the third preset length is controlled to be smaller than the second preset length, interference of the soft jaw chuck during turning is avoided, and therefore machining precision of the gear is controlled to meet the precision requirement of a gear of a vehicle transmission.
Optionally, in step S14, the workpiece roughness of the transmission gear is controlled to be not greater than ra1.6, so as to ensure that when the first end surface of the bar is machined by using the soft jaw chuck in S12, the machining precision of the tooth blank meets the precision requirement of the transmission gear of the automobile, and the high-precision tooth blank is provided as a subsequent machining basis.
Optionally, in executing step S14, the runout of the soft jaw chuck is controlled to be less than or equal to 0.01mm, and the verticality between the inner hole of the chuck and the end face of the chuck is controlled to be less than or equal to 0.005mm, so as to ensure that the precision of the tooth blank obtained by using the improved soft jaw chuck to clamp the tooth blank and turning the tooth blank in step S14 meets the requirement of the automobile transmission gear.
And S2, hobbing the gear surface by using a hobbing machine.
Optionally, in executing step S2, the coaxiality of the first end surface of the tooth blank and the inner hole of the tooth blank is controlled to be less than or equal to 0.01mm, so as to ensure that the gear machining precision meets the gear precision requirement of the automobile transmission, and avoid bad engagement and gear impact during the gear operation.
And S3, heat treatment.
Alternatively, the gear heat treatment is often performed by quenching, considering that the transmission gear requires higher strength to withstand high load operating conditions.
And S4, grinding.
Optionally, in the step S4, the inner hole and the inner hole end face are used for positioning and processing the heat-treated tooth blank by using an inner cone and outer cone combined grinding machine, the roundness of the inner hole of the processed tooth blank is controlled to be within 0.005, the cylindricity is controlled to be within 0.01, the perpendicularity of the second end face and the inner hole is controlled to be within 0.005, and the gear precision after grinding processing can reach more than six stages, so that the gear can meet the precision requirement of the gear processing of the automobile transmission.
And S5, machining the surface of the semi-finished gear subjected to heat treatment by using a forming gear grinding machine to obtain the transmission gear with more than six stages of precision. And (3) processing the surface of the semi-finished gear after heat treatment by adopting a forming gear grinding machine, wherein the gear grinding is used as the last procedure of gear hard tooth surface processing so as to correct errors before gear grinding and obtain high gear precision.
Optionally, before machining by using a gear grinding machine, the shape of the grinding wheel is trimmed by controlling the trimming wheel so as to generate a certain amount of distortion in the grinding process to reduce the natural distortion of the gear, and the machining precision of the gear is improved, for example, in the grinding wheel trimming strategy, the trimming of a pressure angle can be performed along the axial direction of the grinding wheel, and a certain amount of distortion is generated in the grinding process through the pressure angle change of the grinding wheel, so that the distortion is superimposed on the natural distortion, the compensation of the distortion is realized, and the tooth profile parameter of the trimmed grinding wheel along the axial direction and the trimming amount of the gear along the tooth width direction maintain a strict corresponding relation.
Specifically, step S5 includes the steps of:
s51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feeding amount ratio of the dressing wheel when the grinding wheel rotates once.
S52, performing rough grinding and fine grinding on the surface of the semi-finished gear by using the trimmed grinding wheel.
When the linear speed direction of the dressing wheel is the same as that of the grinding wheel, the distance between the protruding high points (wave crests) and the recessed low points (wave troughs) on the surface of the grinding wheel after dressing is the largest, the surface of the grinding wheel is sharper, the grinding efficiency is high, and the grinding wheel is suitable for rough grinding. Alternatively, when the rough grinding process is performed, the linear velocity ratio is configured to be 0.8 to improve the gear rough grinding process efficiency and shorten the rough grinding process time.
When the linear speed direction of the dressing wheel is opposite to that of the grinding wheel, the distance between the protruding high points (wave crests) and the recessed low points (wave troughs) on the surface of the grinding wheel after dressing is small, which indicates that the surface of the grinding wheel is smoother and more flush, which is beneficial to improving the roughness of the tooth surface when grinding a workpiece, but has low grinding efficiency and is suitable for finish grinding. Optionally, the linear speed ratio is configured to-0.8 when performing the lapping process to improve the gear lapping effect and ensure accuracy compliance with the transmission gear accuracy requirements.
Further, the dressing degree of the dressing wheel by the dressing wheel can be controlled by controlling the feed amount ratio of the dressing wheel per one revolution of the grinding wheel to match the requirement of the tooth grinding process, alternatively, the feed amount ratio of the dressing wheel per one revolution of the grinding wheel is configured to be 6 when the rough grinding process is performed using the tooth grinder; in performing the finish grinding process, the feed amount ratio of the dresser disk per one revolution of the grinding wheel is configured to be 10.
Optionally, in order to improve the grinding accuracy, before executing step S5, the fixture accuracy is adjusted to be within 0.003mm, and after the inner hole is expanded by the expansion sleeve 6, the tip 7 is used to jack the expansion sleeve, and the second end face is used as a positioning face for grinding.
Optionally, in executing step S5, the tooth form inclination deviation is controlled within 5 levels, the tooth direction helix angle deviation is controlled within 6 levels, the accumulated deviation of the peripheral knots is not more than 4 levels, and the tooth form drum shape is less than 0.008mm, so as to ensure that the gear processed in step S5 meets the precision requirement of the transmission gear.
The foregoing has outlined a detailed description of a method for rapid manufacturing and machining of a high-precision transmission gear and the transmission gear, wherein specific examples are provided herein to illustrate the principles and embodiments of the present invention, and the above examples are provided to assist in understanding the core idea of the present invention; also, as will be apparent to those skilled in the art in light of the present teachings, the present disclosure should not be limited to the specific embodiments and applications described herein.
Claims (6)
1. The rapid trial-manufacturing processing method of the high-precision transmission gear is characterized by comprising the following steps of:
step S1, clamping a gear bar by using a soft jaw chuck, and performing rough machining and finish machining to obtain a gear blank;
step S2, hobbing;
s3, heat treatment;
s4, grinding;
step S5, grinding teeth on the surface of the semi-finished gear subjected to heat treatment by using a forming gear grinding machine to obtain a transmission gear with more than six stages of precision; wherein, the rough machining in the step S1 comprises the following steps:
s11, the gear bar material penetrates into the soft jaw chuck with a first preset length and is clamped by the soft jaw chuck to form an excircle of the bar material, and a first end face of the bar material protrudes outwards from the chuck;
s12, turning an inner hole of a gear, a first end face of a gear bar and an outer circle of the bar, wherein a machined surface of the outer circle of the bar extends from the first end face of the bar to the second end face of the bar for a second preset length, the sum of the first preset length and the second preset length is controlled to be smaller than the width of the bar, and in the S12 step, the coaxiality of the first end face and the inner hole is controlled to be smaller than or equal to 0.01mm, and the roughness of a gear workpiece of a transmission is controlled to be not larger than Ra1.6;
the finishing in step S1 comprises the steps of:
s13, machining the inner side of the soft jaw chuck, so that the soft jaw chuck stably clamps the outer circle of the workpiece subjected to turning in the S12 in an arc shape;
s14, clamping the gear bar by the surface adjusting device, turning the gear bar into a soft jaw chuck with a third preset length, machining the second end face, controlling the second preset length to be larger than the third preset length, controlling the runout of the soft jaw chuck to be smaller than or equal to 0.01mm, controlling the perpendicularity of an inner hole of the chuck and the end face of the chuck to be smaller than or equal to 0.005mm, and controlling the roughness of the gear workpiece of the transmission to be not larger than Ra1.6.
2. The rapid trial production method of high-precision transmission gears according to claim 1, wherein before the step S5 is performed, the precision of the fixture is adjusted to be within 0.003mm, and after the inner hole is expanded by the expansion sleeve, the center is used for propping the expansion sleeve, and the second end face is used as a positioning face for gear grinding.
3. The rapid prototyping method of high-precision transmission gear as claimed in claim 1, wherein the step S5 comprises the steps of:
s51, dressing the surface of the grinding wheel by controlling the linear speed ratio of the dressing wheel to the grinding wheel and the feeding amount ratio of the dressing wheel when the grinding wheel rotates once;
s52, performing rough grinding and fine grinding on the surface of the semi-finished gear by using the trimmed grinding wheel.
4. The rapid prototyping method of a high-precision transmission gear as claimed in claim 3, wherein the linear velocity ratio is configured to be 0.8 and the feed amount ratio is configured to be 6 when the rough grinding process is performed; when the fine grinding process is performed, the linear velocity ratio is configured to be-0.8 and the feed amount ratio is configured to be 10.
5. A rapid prototyping process for high-precision transmission gears according to claim 3, characterized in that in step S5, the pitch angle deviation is controlled to be within 5 levels, the pitch helix angle deviation is controlled to be within 6 levels, the cumulative deviation of the peripheral nodes is not more than 4 levels, and the tooth crown is less than 0.008mm.
6. A high precision transmission gear produced by the rapid prototyping method of the high precision transmission gear as claimed in any one of claims 1 to 5.
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| CN115091150A (en) | 2022-09-23 |
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