Research On Nc Shaping Method And Processing Simulation Of Cosine Gear

A variety of new arbitrarily tooth gear has been widely used to compensate the shortcomings of involute gear profile and meet all kinds of different usage occasions, to which new difficult problems of manufacturing the current gear are put forward. According to the traditional gear meshing principle and processing methods, conjugated special tool must be manufactured in various new gear generative processing and also different types of gear cutting tools is needed with different modulus, which cause the huge investment costs, long development cycle, tool management problems, etc. and restrict variety of new arbitrarily tooth gear from laboratory into actual production application. The research on new generation methods of the new arbitrarily tooth profiles becomes not only a key problem for the application but also an important issue for designing and manufacturing the new arbitrarily tooth profiles. In view of this, the cosine gear shaping method and processing error analysis are extensively analyzed and discussed in the paper.(1) Research on generative mechanism of the cosine gear shapingBased on discrete digital conjugate theory and CNC machining techniques , the conjugated envelope movement relationship between digital tooth surface and cutting face of cosine gear is investigated, and common digital processing theory and methods of the arbitrarily gear tooth profile are explored. With the combination of conjugated surface theory and the gear shaping technology, mathematic model of the cosine gear digital shaping is established. Without considering slotting interference, simulation of cosine gear slotting process is conducted by adopting MATLAB, which provides theoretical and methodological guidance for the cosine gear digital shaping and practical application.(2) Tooth profile error calculation and analysis for cosine tooth gear shapingWith the combination of generalized deterministic multi-body system kinematics theory and gear meshing theory, constant system and cyclical nature errors caused by geometry eccentric, rotational error and force induced deformation in slotting process are analyzed, mathematic model of each processing error is established based on the above foundation, and then geometry eccentric, rotational error and force induced deformation in slotting process is discussed respectively, the influence degrees and its changing laws of error sources on machining errors are obtained, which provide numerical basis for the subsequent cosine gear cutting processing error compensation.(3) The cosine tooth gear shaping CAM systems and processing simulationThe cosine gear digital tooth shaping CAM system is developed by joint programming of VC + + and MATLAB. The parameters of work piece are input through the dialog interface, and then the G code file of cosine gear shaping is generated automatically. The two-dimensional tool path dynamics cutting envelope is simulated. The parts of the gear shaper is modeled by using Pro / E, and CNC gear shaper virtual simulation platform is created by using Vericut simulation software. The correctness and feasibility of processing methods of digital cosine gear shaping is verified by Vericut CNC machining simulation software, which is prepared for the following actual production process.