Research On Manufacturing Technology Of Cemented Carbide Pinion Cutter With Convex Curved Rake Face

Gear shaping is an important method for gear manufacturing, the use of pinion cutter with new profile of convex curved rake face can increase the tool life and manufacturing precision.In this paper, the precision manufacturing of pinion cutter with convex curved rake face was researched.The special machine tool was developed and the experiment was done.In this paper, the new profile of rake face of pinion cutter was analyzed using the envelope theory of the family of space surfaces, this paper demonstrated the mathematical model of the rake face and established the manufacturing coordinate system.According to the configuration of pinion cutter,designed the experimental scheme to verify manufacturing method of convex curved rake face of pinion cutter,through two kinds of experiment with different materials and process parameters, the result shows that the machine with three servo axis(two linked) can meet the machining demands, based on the experiment,the general scheme of the machine was designed, the parts of the machine was designed in detail,the wheel axis rotation could be controlled and adjusted by designed machinery structure, the machine mode analysis was done by using FEM.The reinforcement treatment of the weakness of the machine structure was done according to the analyzed results.The positioning accuracy, repetitive positioning accuracy and spindle run-out error was tested for the machine, the test results show that the machine could satisfy the machining demands.The mode test for the spindle and grinding wheel axis was done by using experiment analysis method.The method of force-hammer excitation was adopted to finish transient analysis, throuth the measurement of the excitation, the excitation signal of force-hammer and acceleration response was got, then the analysis of transfer function was done. According to the analysis results,the mode analysis and fitting was done, so obtained the mode parameters of spindle and grinding whell axis.According to the pinion cutter characteristic and machine structure,the method to test original position of grinding wheel was designed.The tool setting device was developed by using laser sensor, combination with servo control about the degree of spindle.the original position of the grinding wheel was precisely located,it could improve the manufacturing precision of pinion cutter.The NC code creation system was designed and developed under the DELPHI development platform.The manufacturing experiment was done with different grinding process parameters.the relation curve between surface roughness and gringding parameters was obtained,in order to get better surface quality,the ideal values of rotational speed and grinding federate should be4500r/min and10～15mm/min. Gear shaping experiment was done by using the manufactured pinion cutter.The experiment results show that the pinion cutter was manufactured with higher shaping precision and ability of breakage resistance and wear resistance.