A precision generating hobbing method for face gear with assembly spherical hob

Abstract

In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear, a precision generating hobbing method for face gear with the assembly spherical hob is proposed. Firstly, the evolution of the cylindrical gear to spherical hob basic worm is analyzed, then the spherical hob basic worm is designed, thus the basic worm and spiral angle equation of spherical hob are obtained. Secondly, based on the design method of the existing hob, the development method of the assembly spherical hob is analyzed, the cutter tooth and the cutter substrate of the assembly hob are designed, and the whole assembly is finished. Thirdly, based on the need of face gear hobbing, a numerical control machine for gear hobbing is developed, and the equation of the face gear is obtained. Fourth, for reducing the face gear processing errors induced by equivalent installation errors, the error analysis model is established and the impacts of each error on the gear tooth surface are analyzed. Finally, the assembly spherical hob is manufactured and the gear hobbing test is completed. According to the measurement results, the processing parameters of face gear hobbing are modified, and the deviation of tooth surface is significantly reduced.

Keywords

face gear / spherical hob basic worm / assembly spherical hob / error analysis / hobbing machine

References

[1] HabibiM, ChenZ C. A new approach to blade design with constant rake and relief angles for face-hobbing of bevel gears [J]. Journal of Manufacturing Science & Engineering, 2016, 138(3): 031005

[2] ShihY P, HuangY C, LeeY H, WuJ M. Manufacture of face-hobbed straight bevel gears using a six-axis CNC bevel gear cutting machine [J]. International Journal of Advanced Manufacturing Technology, 2013, 689-122499-2515

[3] BodzásS, DudásI. Mathematical description and modeling of a tooth surface of spiroid face gear having arched profile in axial section [J]. International Journal of Advanced Manufacturing Technology, 2016, 84(5-8): 1431-1442

[4] LiuG Y, WeiW J, DongX Z, RuiC J, LiuP Y, LiH T. Relief grinding of planar double-enveloping worm gear hob using a four-axis CNC grinding machine [J]. International Journal of Advanced Manufacturing Technology, 2016, 89(9-12): 1-10

[5] ZhengF Y, GuoX D, ZhangM D, ZhangW Q. Research on the mold release motion for spiral bevel gear forging [J]. International Journal of Mechanical Sciences, 2018, 136(2): 482-492

[6] ShihY P, SunZ H, WuF C. A disk tool cutting method for bevel gear manufacture on a five-axis machine [J]. International Journal of Advanced Manufacturing Technology, 2018, 94(1): 1-11

[7] ZhaoN, GuoH, FangZ D. Research on machining face gears using a CNC hobbing machine [J]. Advanced Materials Research, 2010, 97-101: 3761-3764

[8] YangX Y, TangJ Y. Research on manufacturing method of CNC plunge milling for spur face-gear [J]. Journal of Materials Processing Technology, 2014, 214: 3013-3019

[9] ZanziC, PedreroJ I. Application of modified geometry of face gear drive [J]. Computer Methods in Applied Mechanics and Engineering, 2005, 194(27): 3047-3066

[10] TsayM F, FongZ H. Novel profile modification methodology for moulded face-gear drives [J]. Journal of Mechanical Engineering, 2007, 221: 715-725

[11] ChenS Y, TangJ Y, ChenW T, HuZ H, CaoM P. Nonlinear dynamic characteristic of a face gear drive with effect of modification [J]. Meccanica, 2014, 49(5): 1023-1037

[12] CuiY M, FangZ D, SuJ Z, FengX Z, PengX L. Precise modeling of arc tooth face-gear with transition curve [J]. Chinese Journal of Aeronautics, 2013, 26(5): 1346-1351

[13] LinC, FanY, ZhangZ W, FuG, CaoX J. Additive manufacturing with secondary processing of curve-face gears [J]. International Journal of Advanced Manufacturing Technology, 2016, 86(1-4): 1-12

[14] TangJ, YangX. Research on manufacturing method of planing for spur face-gear with 4-axis CNC planer [J]. International Journal of Advanced Manufacturing Technology, 2016, 82(5-8): 847-858

[15] ShenY B, LiuX, LiZ P, LiD Y. Research on shaving processing of spiroid face gear [J]. International Journal of Advanced Manufacturing Technology, 2017, 92(1-4): 605-613

[16] PengX L, NiuQ Y, GuoW, FangZ D. A new method of motion rule synthesis for face gear manufacturing by plane-cutter [J]. Journal of Mechanical Design, 2018, 140(2): 023302

[17] ShenY B, LiuX, LiD Y, LiZ P. A method for grinding face gear of double crowned tooth geometry on a multi-axis CNC machine [J]. Mechanism & Machine Theory, 2018, 121460-474

[18] ZhouY, TangJ, ZhouH, YinF. Multistep method for grinding face-gear by worm [J]. ASME. Journal of Manufacturing Science and Engineering, 2016, 138(7): 071013

[19] WuC H, WangY Z. The aeronautics face-gear NC hobbing machining technology [J]. Proceedings of SPIE-The International Society for Optical Engineering, 2013, Singapore, ICGIP: 876828

[20] WangY Z, HouL W, LanZ, WuC H, LvQ J, ZhaoX F. A precision generating hobbing method for face-gear based on worm hob [J]. ARCHIVE Proceedings of the Institution of Mechanical Engineers Part C: Journal of Mechanical Engineering Science, 2016, 2316979-994

[21] WangY Z, HouL W, LanZ, ZhuC L. Precision milling method for face-gear by disk cutter [J]. International Journal of Advanced Manufacturing Technology, 2017, 89(5-8): 1-14

[22] WangY Z, LanZ, HouL W, ZhaoH P, ZhongY. A generating milling method for a spur face gear using a five-axis computer numerical control milling machine [J]. Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 2016, 230(8): 1359-1371

[23] WangY Z, HouL W, LanZ, ZhangG R. Precision grinding technology for complex surface of aero face-gear [J]. International Journal of Advanced Manufacturing Technology, 2016, 86(5-8): 1-10

[24] WangY Z, LanZ, HouL W, ZhaoH P, ZhongY. A precision generating grinding method for face gear using CBN wheel [J]. International Journal of Advanced Manufacturing Technology, 2015, 79(9-12): 1839-1848

[25] WangY Z, LanZ, HouL W, ChuX M, YinY Y. An efficient honing method for face gear with tooth profile modification [J]. International Journal of Advanced Manufacturing Technology, 2017, 90(1-4): 1155-1163