Simulation And Experimental Research Of Virtual Motion Machining Process Of Spiral Bevel Gear Based On UG

Spiral bevel gears have the advantages of high load carrying capacity,long service life and high efficiency,and are widely used in aerospace,engineering machinery,vehicles,ships and other fields.However,due to the complex shape of the tooth surface of spiral bevel gears,there are many problems such as poor machining quality,long machining cycle and high cost in actual machining.Therefore,based on the actual machining of spiral bevel gears,it is important to study the theory and method of virtual machining of spiral bevel gears to improve the gear machining quality,shorten the machining cycle and reduce the production cost.This thesis firstly establishes a spiral bevel gear virtual machining motion model based on the spiral bevel gear meshing principle,machining principle and local synthesis method;secondly,it realizes the spiral bevel gear virtual machining simulation by using UG secondary development technology and obtains a solid gear model;then it uses ABAQUS software to carry out tooth contact analysis on the solid gear model;finally,it carries out gear cutting and machining on the spiral bevel gear milling machine Finally,a gear cutting test was conducted on a spiral bevel gear milling machine.The main research contents of this thesis are as follows:(1)Based on the meshing principle of spiral bevel gears,the basic equation of gear meshing is derived;the principle of spiral bevel gear machining,machining methods and machine tool adjustment parameters are briefly introduced;based on the basic principle of the local synthesis method,the formulae for calculating the main direction and main curvature between the tooth surfaces in line contact and the formulae for calculating the main direction and main curvature between the tooth surfaces in point contact are derived.(2)Calculation of geometric and machining parameters of spiral bevel gears.The geometric parameters of the gear pair are obtained according to the basic parameters of the spiral bevel gear and the calculation formula of geometric parameters;the large wheel machining motion model is established according to the principle of tooth cutting by the spreading method,and the machining parameters of the large wheel are obtained;the equations of the large wheel tooth surface,the main direction and main curvature at the reference point of the large wheel tooth surface and the main direction and main curvature at the reference point of the small wheel tooth surface are derived respectively based on the local synthesis method,and the small wheel machining parameters are established on this basis.The machining motion model of the pinion is established on this basis,and the machining parameters of the pinion are obtained according to the geometric parameters of the pinion teeth;verified the accuracy of machining parameters using TCA technology.(3)Virtual machining simulation of spiral bevel gears.Parametric modeling program was written by using UG secondary development tools,and the solid models of tooth blanks and cutter discs were obtained according to the geometric parameters of tooth blanks and cutter discs;virtual machining simulation of spiral bevel gears was realized by copying rotation,Boolean subtraction operation and cycle commands according to the spiral bevel gear machining parameters and machining motion model,and the solid models of virtual cut gears were obtained,and the virtual The solid model of the virtual cut gear is obtained,and the tooth surface reconstruction of the virtual cut tooth surface is carried out based on the NURBS principle.(4)Spiral bevel gear tooth contact analysis.Hyper mesh software was used to mesh the solid model of the gear to obtain the hexahedral mesh model of the spiral bevel gear,and it was imported into ABAQUS software for static simulation to obtain the distribution law of tooth contact stress and bending stress.In addition,the distribution of tooth surface stresses and the change law under different working conditions were also analyzed.(5)Spiral bevel gear tooth cutting test.On the spiral bevel gear milling machine,the relative positions of the tooth blank and the tool were adjusted according to the gear processing parameters to complete the gear cutting of the spiral bevel gear,and the gear contact area was obtained through the roll inspection test to verify the feasibility of virtual processing of the spiral bevel gear and the accuracy of the processing parameters.