Research On The New Machining Methods And Key Technology Of Spiral Bevel Gears

The algorithm for the calculation of coordinates of gear tooth surfaces base on both the generating surface and B-spline interpolation are studied in detail, and the applicability of the methods are discussed as well. To solve the refinement problem of hardened tooth surfaces of Gleason spiral bevel and hypoid gears, honing technology is suggested to be adopted for the purpose in this thesis, meanwhile, the optimal design and synthesis methods of horning wheels are studied and the special problems in the arts for the manufacture of horning wheels such as stripping interference, interference relieving methods and the manufacture method of metal die are also studied. The machining method of the horning wheels based on Gleason spiral bevel gear generators are studied in a deepgoing way, the corresponding algorithms to obtain the geometric parameters of both the workpiece and honing wheels, and the parameters of cutter head and machine setting for the machining of horning wheels are introduced in details. In order to solve the art problems in the manufacture of large scale and single or small batch spiral bevel gears as well as diamond dressing wheels, a manufacture system based on general end mills are established, the problems in tool track layout and the tool pose determination for both roughing and finishing process are studied in a deepgoing way. The research achievement has been put into practice on a 5-axis machining center, and the machining example indicates that the theoretical analysis, mathematical model of tooth surfaces, algorithm to calculate tool position are correct, not only the suggested machining method of spiral bevels based on general end mills is feasible, but also economical, efficient and fast response for certain situation.