| With more and more attention paid to clean energy,the wind power industry has welcomed its own spring.And each company increases its capacity gradually.However,limited by equipment,site and capital,the production capacity of enterprises is greatly restricted.Gear parts in wind turbine gearboxes are important parts that restrict the capacity of wind power enterprises.How to increase production capacity under current conditions has become the focus of every enterprise's research.At present,the method adopted by enterprises in prototype trial-manufacture and rough and semi-finish machining of parts is to process various parts by using substitute disc type gear milling cutter.Substitute disc type gear milling cutter is a kind of gear cutter which has same shape and size with specified disc type gear milling cutter,but its modulus and tooth number are similar to the specified one.In this way,the production cycle can be reduced and the production cost is saved.However,because of the different parameters of various gear parts,the profile errors between the disc type gear milling cutter and the workpiece are existed.In actual production,the trial cutting method is usually adopted when the substitute disc type gear milling cutter is used to process different parts.And the trial cutting method usually needs multi-times feed processes to find and determine the processing law.By analyzing the cutting depth and the minimum tooth profile distance,an optimal scheme is selected to the trial process.The trial cutting method not only takes a longer machining time but also increases the processing cost of the enterprise.Furthermore,there is no accurate and intuitive data for the location of tooth root and so on.In order to solve this production bottleneck,in this paper,we hope to establish a parametric modeling and tooth profile comparison system to replace the specified disc type gear milling cutter.Through parameter driving,three-dimensional simulation and software calculation,we can realize the model generation and distance calculation of the tooth profile between the milling cutter and the gear tooth profile.Therefore,the processing time and cost of the enterprise are shortened.In this paper,the profiles of the substitute disc type gear milling cutter and gear are analyzed theoretically,and the calculating equation of involute tooth profile is solved according to the generating theory.In the process of calculating tooth profile,the enterprise calculating requirements for the arc,angle and settling amount of tooth top are added.Several typical machining methods used in practice are explained in detail and compared.A three-dimensional modeling and tooth profile comparison system for the substitute disc type gear milling cutter is developed by using SOLIDWORKS and VB software.Input modulus,tooth number,modification coefficient,helix angle,shape dimension,etc.parameters of workpiece and tool,the system can directly generate three-dimensional model.Through cutting depth controlling,the output of tooth profile comparison data of the disk type gear milling cutter and the gear is realized,and the tooth profile distance data of several special points under different cutting depth are calculated.As an example,the inner gear ring with normal modulus 16 and disc type gear milling cutter with normal modulus 14 are input into the system.According to the data calculated by the system,the production is guided by the data in the actual process of machining.The data obtained are basically consistent with the requirements of processing.Therefore,the design principle and theoretical calculation of the system are correct,and the data obtained can meet the requirements for guiding production. |
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