Research On Processing Technology Of Klingelnberg Cyclo-Palloid Bevel Gears Based On Monolithic Cutter

In recent years, the industry such as petroleum, mining, metallurgy and etc, developed rapidly in our country. As a result, the requirements for large size and high precision spiral bevel gears grow fast as well. The Klingelnberg tooth system is used for this kind of gear in abroad. At present, Klingelnberg corporation has the complete technology and equipment for realizing digital close loop manufacturing, including design, manufacture, measurement, error analysis of cyclo-palloid bevel gears and blade sharpening and inspection.Domestic CNC spiral bevel gear milling machine can not process cyclo-palloid bevel gears with two-part cutter until now, because of the restriction of machine’s structure. In order to break up the technical monopoly of foreign companies, improve the independent innovation capacity of CNC machining equipment of cyclo-palloid bevel gears, and process cyclo-palloid bevel gear on the domestic five-axis simultaneous CNC spiral bevel gear cutting machine, this thesis researched the processing technology of cyclo-palloid bevel gear with monolithic cutter. The research results involves:1) Based on the machining principle of cyclo-palloid bevel gears, the processing method of cyclo-palloid bevel gears with monolithic cutter was researched. Based on the forming principle of cyclo-palloid bevel gear’s tooth line, the thesis established a processing method that the gear was processed by double side method, the pinion’s roughing was achieved by double side method and the pinion’s finishing was accomplished by single side method. This processing method modifies only pinion’s tooth surface curvature and can achieve local conjugate contact of gear pair. The formulae were derived for calculating the cutter-head and machine setting parameters, and VB 6.0 was used to develop the corresponding calculation software.2) The mathematical model of tooth profile was built based on cutting principle of cyclo-palloid bevel gears and gear meshing theory. In order to realize precise measurement of tooth profile errors, the tooth surface of cyclo-palloid bevel gear was discretized and the method for calculating the spatial coordinates and normal vector was proposed. The software was developed for calculating the spatial coordinates and normal vector of theoretical tooth surface in VB 6.0 programming environment.3) The design method for soft cutting blade of monolithic cutter was proposed. Based on the forming principle of soft cutting blade, the processing principle of soft cutting blade with offset disc was researched. The impact of machining errors on cutter radius was analyzed. The sharpening principle of soft cutting blade was built and the calculation formulae for sharpening fixture adjustment block was derived.4) The experiment of cutting was done on domestic five-axis simultaneous CNC bevel gear cutting machine with monolithic cutter. The correctness of the cutting principle with monolithic cutter is verified by the result of rolling test of gearset. The tooth profile errors of practical cyclo-palloid bevel gears were measured on gear measuring center. The measuring result verifies that the tooth profile mathematical model is correct and lays a foundation for the realization of digital manufacturing of cyclo-palloid bevel gears.