CN1063696C - Electric spark staggered expansion machining method of fine-pitch involute gear - Google Patents

Electric spark staggered expansion machining method of fine-pitch involute gear Download PDF

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CN1063696C
CN1063696C CN95112710A CN95112710A CN1063696C CN 1063696 C CN1063696 C CN 1063696C CN 95112710 A CN95112710 A CN 95112710A CN 95112710 A CN95112710 A CN 95112710A CN 1063696 C CN1063696 C CN 1063696C
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云乃彰
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Nanjing University of Aeronautics and Astronautics
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Abstract

一种小模数渐开线齿轮的电火花交错展成加工方法属小模数齿轮电火花加工方法。工艺流程为：设计电火花交错展成加工用齿条电极；用快速走丝线切割工艺制作齿条电极；机械加工齿轮毛坯；在数控电火花成形机上完成电极与工件安装及找正；编制数控电火花成形加工程序，以放电蚀除完成渐开线小模数齿轮的成形。该工艺由于齿条电极模数扩大，相应齿距也扩大，电极齿根部位移的线切割工艺条件大为改善，齿轮模数、压力角、齿数可按需要改有关程序。

The invention relates to an electric spark interleaved generating machining method for small modulus involute gears, which belongs to the small modulus gear electric spark machining method. The technological process is as follows: design the rack electrode for EDM interlaced generation processing; manufacture the rack electrode with the fast wire cutting process; machine the gear blank; complete the installation and alignment of the electrode and the workpiece on the CNC EDM machine; The spark forming processing program uses electric discharge erosion to complete the forming of involute small modulus gears. In this process, due to the expansion of the rack electrode modulus, the corresponding tooth pitch is also enlarged, and the wire cutting process conditions for the displacement of the electrode tooth root are greatly improved. The gear modulus, pressure angle, and number of teeth can be changed according to the relevant procedures.

Description

小模数渐开线齿轮的电火花交错展成加工方法EDM Interleaved Generation Machining Method for Small Modulus Involute Gears

本发明的小模数渐开线齿轮的电火花交错展成加工方法属于小模数齿轮的电火花加工方法。The electric spark interleaved generation machining method of the small modulus involute gear of the present invention belongs to the electric spark machining method of the small modulus gear.

小模数渐开线齿轮常用机械加工方法为切削加工，适用大多数制造对象。但对于材料特硬或过软，被加工齿轮的模数、压力角不在标准系列、小批量或单件生产无相应刀具，以及齿轮结构特殊(如多连，不允许开退刀槽等)时无法应用。The common machining method for small modulus involute gears is cutting, which is suitable for most manufacturing objects. However, when the material is extremely hard or too soft, the modulus and pressure angle of the gear to be processed are not in the standard series, there is no corresponding tool for small batch or single-piece production, and the gear structure is special (such as multi-connection, it is not allowed to open the undercut, etc.) Unable to apply.

电火花线切割在弥补上述不足时有良好作用，仍存在对特殊结构(如非贯通类齿轮、例双连、盲孔型内齿等)及很小模数时的使用限制，同时，齿表面粗糙度不够理想。WEDM plays a good role in making up for the above shortcomings, but there are still restrictions on the use of special structures (such as non-through gears, double-connected, blind-hole internal teeth, etc.) and small modulus. At the same time, the tooth surface The roughness is not ideal.

电火花展成加工克服了上述大部分工艺难点，但对微型齿形(较小模数)加工受电极制造时电极丝径制约，仍有不可加工范围。EDM has overcome most of the above-mentioned technical difficulties, but the processing of micro-tooth (smaller modulus) is restricted by the diameter of the electrode wire during electrode manufacturing, and there is still an unmachinable range.

本发明的任务在于扩大特种加工工艺在小模数齿轮制造的途径，提高加工柔性和效率，保证加工质量。The task of the invention is to expand the way of special processing technology in the manufacture of small modulus gears, improve processing flexibility and efficiency, and ensure processing quality.

本发明的小模数渐开线齿轮的加工方法，采用电火花交错展成加工方法，其工艺是，在已知待制造齿轮的模数、齿数、压力角等基本参数的条件下，采用以下工艺流程：The processing method of the small modulus involute gear of the present invention adopts the EDM interlaced generation processing method, and its process is that under the condition of knowing the basic parameters such as the modulus, the number of teeth, and the pressure angle of the gear to be manufactured, the following Process flow:

1．设计电火花交错展成加工用的齿条电极，包括确定交错展成比，计算电极齿形等；1. Design the rack electrode for EDM interleaving generation machining, including determining the interleaving generation ratio, calculating the tooth shape of the electrode, etc.;

2．使用快速走丝线切割工艺制作齿条电极；2. Fabricate rack electrodes using fast wire cutting process;

3．机械加工齿轮毛坯；3. Machining gear blanks;

4．在数控电火花成形机上完成电极与工件的安装及找正；4. Complete the installation and alignment of electrodes and workpieces on the CNC EDM;

5．编制数控电火花成形加工程序，包括选择与变更电规准，指定各轴运动方式，以放电蚀除完成渐开线小模数齿轮的成形。5. Compilation of NC EDM program, including selection and change of electrical standards, designation of movement modes of each axis, and completion of involute small modulus gear forming by EDM.

附图1，就是电火花展成加工运动方式示意图。Attached drawing 1 is a schematic diagram of the movement mode of EDM machining.

图中1-齿条状电极；2-齿轮毛坯；C-表示运动方向。In the figure, 1-rack-shaped electrode; 2-gear blank; C-represents the direction of motion.

附图2，交错成展示意图。Accompanying drawing 2, the schematic diagram of staggered formation.

关于确定交错展成比以及电火花交错展成加工用电极的齿形与常规传动齿轮齿形的换算有如下推导：There are following derivations on the determination of the staggered generation ratio and the conversion between the tooth shape of the electrode used for EDM staggered generation machining and the tooth shape of conventional transmission gears:

在一般的机械加工电火花展成加工齿轮时，都必须满足工具或电极与被加工齿轮工件的模数相等。但在交错展成电火花加工中，齿条电极的模数则一定有下面的变化。即：In the general machining of EDM gears, it must be satisfied that the modulus of the tool or electrode is equal to that of the gear workpiece to be machined. However, in interleaved generation EDM, the modulus of the rack electrode must have the following changes. Right now:

mE=nmw     (1)m E = nm w (1)

J=Zw/n     (2)式中，mE-齿条电极模数，mm；J=Z w /n (2) In the formula, m E - rack electrode modulus, mm;

mw-齿轮工件模数，mm；m w - gear workpiece modulus, mm;

J-交错展成比，必须为既约分数；J-The staggered expansion ratio must be a reduced fraction;

Zw-齿轮工件齿数；Z w - the number of teeth of the gear workpiece;

n-正整数。n - positive integer.

表1齿条齿形尺寸计算 项    目     齿形1     齿形2     齿形3     齿形4 齿顶高ha ha1=ha *mw ha2=(ha *+c*)mw ha3=ha2-SF ha4=ha2-SF 齿根高hf hf1=(ha *+c*)mw hf2=ha *mw hf3=hf2+SF hf4=hf2+SF 齿高h h1=ha1+hf1 h1=ha2+hf2 h3=h2=h1 h4=h3 齿距P P1=mwπ P2=mwπ P3=P2 P4=mEπ 齿形角a a1=aw a2=aw a3=aw a4=aw 节线齿厚S S1=P1/2 S2=P2/2 S3=S2-2SF/cosa S4=S3 齿顶齿厚Sa Sa1=S1-2ha1tga Sa2=S2-2ha2tga Sa3=S3-2ha3tga Sa4=Sa3 齿根齿厚Sf Sf1=S1+2hf1tga Sf2=S2+2hf2tga Sf3=S3+2hf3tga Sf4=Sf3 Table 1 Calculation of rack tooth profile size project Tooth profile 1 Tooth profile 2 Tooth 3 Tooth profile 4 Addendum height h a h a1 = h a * m w h a2 =(h a * +c * )m w h a3 =h a2 -S F h a4 =h a2 -S F Dedendum height h f h f1 =(h a * +c * )m w h f2 = h a * m w h f3 =h f2 +S F h f4 =h f2 +S F Tooth height h h 1 =h a1 +h f1 h 1 =h a2 +h f2 h 3 =h 2 =h 1 h 4 =h 3 Pitch P P 1 =m w π P 2 =m w π P 3 =P 2 P 4 =m E π Tooth angle a a 1 =a w a 2 =a w a 3 =a w a 4 =a w Pitch line tooth thickness S S 1 =P 1 /2 S 2 =P 2 /2 S 3 =S 2 -2S F /cosa S 4 =S 3 Tooth top tooth thickness S a S a1 =S 1 -2h a1 tga S a2 =S 2 -2h a2 tga S a3 =S 3 -2h a3 tga S a4 =S a3 Tooth root tooth thickness S f S f1 =S 1 +2h f1 tga S f2 =S 2 +2h f2 tga S f3 =S 3 +2h f3 tga S f4 =S f3

关于电极齿形的计算，因在电火花成形加工中，电极与工件存在放电间隙，所以齿轮传动设计或齿轮机械加工时，齿条(电极)的计算公式，需进行必要的修改，方可应用(详见表1)。Regarding the calculation of the tooth shape of the electrode, since there is a discharge gap between the electrode and the workpiece in EDM, the calculation formula of the rack (electrode) needs to be modified before it can be applied in gear transmission design or gear machining (See Table 1 for details).

表中：ha *-齿顶高系数；In the table: h a * - coefficient of addendum height;

  C*-顶隙系数；C * - headspace coefficient;

  aw-齿轮压力角；a w - gear pressure angle;

  SF-放电加工间隙。S F - EDM gap.

根据表1，齿条电极齿形的设计计算步骤为：According to Table 1, the design and calculation steps of rack electrode tooth profile are as follows:

1．计算等效于传动用齿条的齿形1；1. Calculate the tooth profile 1 equivalent to the transmission rack;

2．计算等效于切削加工用齿条形刀具的齿形2；2. Calculate the tooth profile 2 equivalent to a rack-shaped tool for cutting;

3．计算一般电火花展成加工用齿条电极的齿形3；3. Calculation of the tooth profile of the rack electrode for general EDM machining;

4．计算电火花交错展成加工用齿条电极的齿形4。4. Calculation of the tooth profile of the rack electrode used in EDM interlaced generation machining 4.

交错展成电火花加工的齿条电极由于模数扩大，相应齿距也扩大，当用电火花线切割工艺制作电极时，电极齿根部位移的切割工艺条件大为改善，即使模数很小，也不再受电极丝径的限制。As the modulus of the rack electrode of interlaced generation EDM is expanded, the corresponding tooth pitch is also enlarged. When the electrode is made by the wire electric discharge cutting process, the cutting process conditions for the displacement of the electrode tooth root are greatly improved, even if the modulus is small, It is no longer limited by the diameter of the electrode wire.

在电火花交错展成加工中，考虑了放电间隙，电极的直线位移距离应等于齿轮(毛坯)工件分度圆周长的n倍，以实现准确的相对运动。工件转动一周，其齿廓成形仅是交错分布的若干齿，以后各周再对应去除另一些齿间余量，直至n周后完成整个齿轮的加工。附图2显示的为n=2时交错展成的示例。此图中的3-为齿条电极，4-为齿轮毛坯。根据公式(3)，此时Zw一定为奇数。工件毛坯转动第一周第1，3，5，……，(N+1)/2个齿成形，第二周时，才是第2，4，6，……，(N-1)/2个齿成形，即转动n=2周后完成整个齿轮的齿廓加工。In EDM interlaced generation machining, considering the discharge gap, the linear displacement distance of the electrode should be equal to n times the circumference of the gear (blank) workpiece indexing circle, so as to achieve accurate relative movement. The workpiece rotates once, and its tooth profile is only formed by a number of teeth that are distributed in a staggered manner. After that, other inter-tooth allowances are correspondingly removed in each subsequent cycle, until the processing of the entire gear is completed after n cycles. Figure 2 shows an example of interleaved generation when n=2. 3- in this figure is the rack electrode, and 4- is the gear blank. According to formula (3), Z w must be an odd number at this time. The 1st, 3rd, 5th, ..., (N+1)/2 teeth are formed in the first cycle of the workpiece blank rotation, and the 2nd, 4th, 6th, ..., (N-1)/ Two teeth are formed, that is, the tooth profile processing of the entire gear is completed after turning n=2 weeks.

交错展成运动可采用以下方式组成：Staggered generating motions can be composed in the following ways:

1．依电规准的自粗至精，齿条电极与齿轮工件毛坯的相对进给运动(Y向)，每工步进给不同距离；1. From coarse to fine according to the electric standard, the relative feed movement (Y direction) between the rack electrode and the gear workpiece blank, and the feed distance is different for each working step;

2．完成Y向进给后，电极作X向、工件作C向复合运动，由J决定每工步电极进给距离，及工件旋转周数。机床的精密数控位数系统，保证了各轴同步运动精度。2. After the Y-direction feed is completed, the electrode moves in the X-direction and the workpiece moves in the C-direction. J determines the feeding distance of the electrode in each step and the number of rotations of the workpiece. The precision numerical control digit system of the machine tool ensures the synchronous motion accuracy of each axis.

小模数渐开线齿轮的交错展成电火花加工电极设计制造简捷、精确，齿轮模数、压力角、齿数可按需要更改有关程序。该工艺具有良好的制造柔性。该工艺适合于微型齿形与非贯通齿形的加工。The design and manufacture of interleaved EDM electrodes for small modulus involute gears is simple and precise, and the gear modulus, pressure angle, and number of teeth can be changed as required. This process has good manufacturing flexibility. This process is suitable for the machining of micro tooth profile and non-through tooth profile.

Claims (1)

1．一种小模数渐开线齿轮的电火花交错展成加工方法，其特征在于：1. A small modulus involute gear EDM interleaved generative machining method, characterized in that: (1)设计电火花交错展成加工用的齿条电极，包括确定交错展成比，计算电极齿形，其具体步骤为：(1) Design the rack electrode for EDM interlaced generation machining, including determining the interleaved generation ratio and calculating the electrode tooth shape. The specific steps are: (a)计算等效于传动用齿条的齿形1；(a) Calculate the tooth profile 1 equivalent to the transmission rack; (b)计算等效于切削加工用齿条形刀具的齿形2；(b) Calculate the tooth profile 2 equivalent to the rack-shaped tool for cutting; (c)计算一般电火花展成加工用齿条电极的齿形3；(c) Calculate the tooth shape 3 of the rack electrode for general EDM machining; (d)计算电火花交错展成加工用齿条电极的齿形4。(d) Calculation of the tooth shape 4 of the rack electrode for EDM interlaced generation machining. 上述齿形1至4的齿形结构特征如下表所示： 项    目     齿形1     齿形2     齿形3     齿形4 齿顶高ha ha1=ha *mw ha2=(ha *+c*)mw ha3=ha2-SF ha4=ha2-SF 齿根高hf hf1=(ha *+c*)mw hf2=ha *mw hf3=hf2+SF hf4=hf2+SF 齿高h h1=ha1+hf1 h1=ha2+hf2 h3=h2=h1 h4=h3 齿距P P1=mwπ P2=mwπ P3=P2 P4=mEπ 齿形角a a1=aw  a2=aw a3=aw a4=aw 节线齿厚S S1=P1/2  S2=P2/2 S3=S2-2SF/cosa S4=S3 齿顶齿厚Sa Sa1=S1-2ha1tga Sa2=S2-2ha2tga Sa3=S3-2ha3tga Sa4=Sa3 齿根齿厚Sf Sf1=S1+2hf1tga Sf2=S2+2hf2tga Sf3=S3+2hf3tga Sf4=Sf3
The tooth structure features of the above-mentioned tooth shapes 1 to 4 are shown in the table below: project Tooth profile 1 Tooth profile 2 Tooth 3 Tooth profile 4 Addendum height h a h a1 = h a * m w h a2 =(h a * +c * )m w h a3 =h a2 -S F h a4 =h a2 -S F Dedendum height h f h f1 =(h a * +c * )m w h f2 = h a * m w h f3 =h f2 +S F h f4 =h f2 +S F Tooth height h h 1 =h a1 +h f1 h 1 =h a2 +h f2 h 3 =h 2 =h 1 h 4 =h 3 Pitch P P 1 =m w π P 2 =m w π P 3 =P 2 P 4 =m E π Tooth angle a a 1 =a w a 2 =a w a 3 =a w a 4 =a w Pitch line tooth thickness S S 1 =P 1 /2 S 2 =P 2 /2 S 3 =S 2 -2S F /cosa S 4 =S 3 Tooth top tooth thickness S a S a1 =S 1 -2h a1 tga S a2 =S 2 -2h a2 tga S a3 =S 3 -2h a3 tga S a4 =S a3 Tooth root tooth thickness S f S f1 =S 1 +2h f1 tga S f2 =S 2 +2h f2 tga S f3 =S 3 +2h f3 tga S f4 =S f3
表中，mw为齿轮工件模数；ha *为齿顶高系数；C*为顶隙系数；aw为齿轮压力角；SF为放电加工间隙；mE为齿条电极模数，它等于n倍齿轮工件模数mw，n为正整数；In the table, m w is the gear workpiece modulus; h a * is the tooth top height coefficient; C * is the top clearance coefficient; a w is the gear pressure angle; S F is the discharge machining gap; m E is the rack electrode modulus, It is equal to n times the gear workpiece modulus m w , n is a positive integer; (2)使用快速丝线切割工艺制作齿条电极，电极的直线位移距离应等于齿轮工件分度圆周长的n倍，工件转动一周，其齿廓成形仅是交错分布的若干齿，以后各周再对应去除另一些齿间余量，直至n周后完成整个齿轮的加工；(2) Use the rapid wire cutting process to make the rack electrode. The linear displacement distance of the electrode should be equal to n times the circumference of the indexing circle of the gear workpiece. When the workpiece rotates a circle, the tooth profile is only formed by a number of teeth that are staggered, and then it will be repeated every week. Correspondingly remove other inter-tooth allowances, until the machining of the entire gear is completed after n weeks; (3)机械加工齿轮毛坯；(3) Machining gear blanks; (4)在数控电火花成形机上完成电极与工件的安装及找正；(4) Complete the installation and alignment of electrodes and workpieces on the CNC EDM; (5)编制数控电火花成形加工程序，包括选择与变更电规准，指定各轴运动方式，以放电蚀除完成渐开线小模数齿轮的成形。(5) Compile the CNC EDM program, including selecting and changing the electrical standard, specifying the movement mode of each axis, and completing the forming of the involute small modulus gear by EDM.
CN95112710A 1995-09-28 1995-09-28 Electric spark staggered expansion machining method of fine-pitch involute gear Expired - Fee Related CN1063696C (en)

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EP0357772A1 (en) * 1987-09-14 1990-03-14 NAGATA, Shigeyoshi Hob cutter for cutting involute gear

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SU1407715A1 (en) * 1986-01-28 1988-07-07 Научно-производственное объединение по топливной аппаратуре двигателей "ЦНИТА" Electrode feed device for electro-erosion machine
EP0357772A1 (en) * 1987-09-14 1990-03-14 NAGATA, Shigeyoshi Hob cutter for cutting involute gear
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CN101147992B (en) * 2007-10-24 2010-04-14 广东轻工职业技术学院 Large depth-to-diameter ratio tooth-shaped female die numerical control electric discharge machining device and processing method
CN110744158A (en) * 2019-10-31 2020-02-04 华南理工大学 Electrolytic finish machining method for micro-wire gear
CN110744158B (en) * 2019-10-31 2021-02-12 华南理工大学 Electrolytic finish machining method for micro-wire gear

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