Research On Noncircular Gear Processing Method And Numerical Simulation Of Helical Noncircular Gear Maching Processing

Since non-circular gear has advantages of both cams and gears, it is widely used in the fields of textile machinery, instrument,and products of military industry. Currently it is commonly seen that straight tooth noncircular gears have practical applications while it’s not the case of helical non-circular gears. Related researches of helical non-circular gears mainly focused on deriving of mathematical model and its control model, however it has not been thoroughly studied in terms of analysis on processing procedure, the actual processing, processing simulation. It is easier to design a helical noncircular gear than straight tooth noncircular gear because it introduces an additional parameter "β" and avoids the step of matching the pitch’s length for the design noncircular. In addition, helical non-circular gears drive smoother, make lesser noise and have higher efficiency in transmission. Therefore it is valuable for studying the hob processing of helical non-circular gearsThe paper mainly focused on the following researches:1. Analysis on advantages and disadvantages of equal polar angle and equal arc length processing methods. Through programming with MATLAB languages, the noncircular gear processing in terms of the above two methods was showed and the hidden rules, using only one tooth of slotting cutter to form all of the noncircular tooth profile of envelope tooth and the least tooth of cutter of gear to generate the3d model of helical noncircular gear, was found out.2. A set of W-S algorithm was developed. Using the algorithm and the rule of envelope tooth, a very simple and efficient numerical algorithm for designing the tooth profile was created. At last feasibility and accuracy of this algorithm was confirmed by a computer program developed in MATLAB language.3. Generating a real3d model of the noncircular gear in SolidWorks with the numerical solutions of tooth profile acquired from algorithm programs. Validity of the3d model was confirmed through its kinematics simulation.4.The real3d model of helical noncircular gear was acquaired through VB language to carry on second development of SolidWorks. The development process using the principle of second point and method of development can be used for building concave-convex pitch of noncircular gear.5. Mathematical models of four shaft linkage mathematical model and five linkage mathematical of hobbing cutter for helical noncircular gear were derived and a method of calculating the minimum length of the hobbing cutter in four shaft linkage is put forward. Create simulation of hobbing processing, based on the above two kinds of mathematical model, of a helical noncircular gear using SolidWorks secondary development function by VB language. In addition, the paper compared advantages and disadvantages of the above mathematical model and obtained the optimum application scope of the two hobbing methods separately.6. Based on the quality characteristics during simulation machining process of the gear hobbing and the kinematical analysis of coordinated motion between each axis, the overall project preliminary design of the gear hobbing machine for the helical non-circular gear was introduced in this paper.