CN120516367A - A method for machining large-diameter multi-segment combined gears - Google Patents
A method for machining large-diameter multi-segment combined gearsInfo
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- CN120516367A CN120516367A CN202511013225.5A CN202511013225A CN120516367A CN 120516367 A CN120516367 A CN 120516367A CN 202511013225 A CN202511013225 A CN 202511013225A CN 120516367 A CN120516367 A CN 120516367A
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- gears
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/14—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
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Abstract
本发明涉及一种大直径多段组合式齿轮加工方法，属于组合式齿轮加工技术领域，加工时先对弧段齿块单独进行粗加工和半精加工，中间穿插安排时效处理消除应力，然后将多件弧段齿块拼装成两件半形齿轮，再将两件半形齿轮通过联接工装组装成整圆齿轮，最后采用大型立车和大型滚齿机精加工，精铣齿后直接进入装配，避免了弧段齿块单独加工的变形和拼装时的安装误差，加工后，能够达到零件精度和装配要求，且有效提高了加工效率。
The present invention relates to a method for machining large-diameter multi-segment combined gears, belonging to the technical field of combined gear machining. During machining, the arc segment tooth blocks are first subjected to rough machining and semi-finishing machining separately, with aging treatment interspersed in between to eliminate stress. Then, the multiple arc segment tooth blocks are assembled into two half-shaped gears, and the two half-shaped gears are assembled into a full-circle gear through a connecting tool. Finally, a large vertical lathe and a large gear hobbing machine are used for fine machining. After fine milling of the teeth, the gears are directly assembled, thereby avoiding deformation caused by separate machining of the arc segment tooth blocks and installation errors during assembly. After machining, the part accuracy and assembly requirements can be met, and the machining efficiency is effectively improved.
Description
Technical Field
The invention relates to the technical field of combined gear machining, in particular to a large-diameter multi-section combined gear machining method.
Background
The multi-section combined gear is a common structural form of a transmission part, and is generally formed by combining 6-12 sections of arc-section gear blocks with the same length, a hub and the like, and can form a full circle or a non-full circle, wherein the maximum diameter of the combined gear can reach or exceed phi 16 meters, the gear precision GB/T is 10095-8 level, the tooth shape is generally standard straight teeth, the center of the length of each arc-section gear block is a tooth groove, and the two end faces of the length are half tooth groove structures, and the structural schematic is shown in figures 1 and 2.
The multi-section combined gear is processed by adopting different processing methods according to different combination modes, and the multi-section combined gear with relatively smaller diameter (less than phi 10 meters) similar at home and abroad at present is mostly processed by adopting sections to be singly processed and then assembled for direct use, and each arc section tooth block is processed by adopting a high-precision numerical control processing center and matched with a special cutter for finish machining. The machining method can get rid of dependence on a large vertical lathe and a large gear hobbing machine, but has some problems, and is difficult to ensure the machining precision and a certain degree of interchangeability of a single-section tooth block for a multi-section combined gear with an ultra-large diameter (phi 12-16 m) due to the limitation of the specification of large precise equipment, so that the method has great influence on the use of products.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a large-diameter multi-section combined gear machining method, which can avoid the problems of deformation and assembly errors of the independent machining of the arc section gear blocks and effectively ensure that the machined gear precision meets the requirements.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
A large-diameter multi-section combined gear machining method comprises the steps that a plurality of arc section tooth blocks with the same length are combined through hubs, the central angle is not larger than 180 degrees, during machining, rough machining and semi-finishing are carried out on each arc section tooth block independently, then a plurality of arc section tooth blocks after semi-finishing are assembled into two half-shaped gears through the hubs, the two half-shaped gears are assembled into a full-circle gear with symmetrical tooth parts through a connecting tool, and finally tooth-shaped finish machining is carried out on the full-circle gear, so that tooth shapes meet design requirements.
Further, the rough machining of the arc segment tooth block comprises the following steps:
(1) Rough machining of the appearance of the arc segment tooth block, namely rough machining the appearance thickness, the large end surface of the length end and all parts of the inner circle and the outer circle of the arc segment tooth block in a numerical control planer boring and milling machine, and then performing a hardening and tempering process to ensure the hardness requirement of a drawing;
(2) Semi-finishing the appearance of the arc segment tooth block in a numerical control planer boring and milling machine, wherein the semi-finishing is performed on each part of the large surface and the inner circle and the outer circle of the appearance thickness and the length end of the arc segment tooth block;
(3) Milling a reference tooth groove of the arc section tooth block in a numerical control planer boring and milling machine, leveling and compacting according to the center line and the end face of the arc section tooth block, finding a part rotation center by a machine tool by taking the outer circle of the arc section tooth block as a reference, centering the two ends of the length, milling a groove of each tooth by taking the tooth groove of the length center as a tooth groove of 0 bit, and processing a certain depth to be used as a reference groove, so that the boring machine can find a right cutter for processing;
(4) The tooth grooves are roughly milled by the arc section tooth blocks, the arc section tooth blocks are horizontally placed on a boring machine rotary worktable, the center line of a part and the center line of the rotary worktable are aligned in a parallel state, a finger-shaped milling cutter is assembled on a boring machine spindle, the rotary worktable is combined with translation of a boring shaft according to the included angle of each tooth groove, and the center of each tooth groove is aligned to be consistent with the center of the spindle, so that each tooth groove is processed.
Further, when the tooth grooves are roughly milled by the arc segment tooth blocks, the included angle θ=360°/Z of each tooth groove is the number of whole circle teeth.
Further, semi-finishing of the tooth segment tooth block comprises the following steps:
(1) Semi-finishing the appearance of the tooth block of the arc section, including the thickness of appearance and each part of the inner and outer circles of the big end surface of the length;
(2) Semi-finish milling a reference tooth slot by the arc section tooth block, wherein the method is the same as the rough machining step (3);
(3) And (3) semi-finish milling the tooth slot by the arc section tooth block, wherein the method is the same as the rough machining step (4).
Further, an aging treatment is interposed between the rough machining and the semi-finishing to eliminate machining stress.
Further, when the center angle of the half-shaped gears is the same as that of the combined gears, the centers of the two half-shaped gears are overlapped and the tooth parts are symmetrically arranged when the full-circle gears are assembled, if the center angle of the half-shaped gears is smaller than 180 degrees, two connecting tools are arranged at the gap between the end faces of the two half-shaped gears and are respectively connected with the hubs on the two sides, the two half-shaped gears are assembled into the full-circle gears with symmetrical tooth parts, and if the center angle of the half-shaped gears is equal to 180 degrees, the hubs on the two sides are directly and fixedly connected to form the full-circle gears.
Further, when the central angle of the half-shaped gear is smaller than 180 degrees, the two connecting tools are identical in size and are symmetrically arranged, the connecting tools are designed to be just capable of filling the gaps, and therefore the two half-shaped gears are assembled into the full circle gear with symmetrical tooth parts.
Further, the tooth profile finish machining of the full-circle gear is performed on a large vertical lathe and a large gear hobbing machine, and the tooth profile is ensured to meet the precision requirement after the machining is finished.
Further, when finishing the whole round gear, use special centering mechanism in order to guarantee that the disc milling cutter symmetry center plane passes through the center of revolution of gear being processed, special centering mechanism includes base, telescopic link and V type locating piece, processing has the reference surface of setting a knife on the disc milling cutter, during the use, first install special centering mechanism on gear hobbing machine knife rest, install the disc milling cutter again, adjust the telescopic link and make V type locating piece stretch out and contact with the reference surface of setting a knife of disc milling cutter, check the clearance of disc milling cutter both sides face and V type locating piece both sides face with the clearance of clearance gauge, adjust disc milling cutter position and make the both sides clearance unanimous after, carry out finish milling tooth again.
Further, the tooth shape of the arc section tooth block is a standard straight tooth, the length center of each arc section is a tooth slot, and the two end faces of the length are half tooth slots.
The processing method has the beneficial effects that a set of processing total scheme of the large-diameter multi-section combined gear is provided, the scheme of split individual processing and then assembling into a full circle finish processing is provided, after semi-finish processing, a plurality of arc section gear blocks are assembled into a half-shaped gear, and two small semicircular half-shaped gears with weaker rigidity are assembled into a large gear through tool connection for finish processing, so that deformation of the arc section gear blocks during individual processing and installation errors during assembling are avoided, and the part precision and assembly requirements of drawings can be met after processing.
The invention provides a method for rough machining and semi-finishing tooth shapes of arc-segment tooth blocks, which is characterized in that a numerical control planer boring and milling machine is matched with a finger-shaped milling cutter to perform rough machining and semi-finishing on the arc-segment tooth blocks step by step, an aging treatment is arranged in a penetrating way to eliminate stress, the gear is gradually removed and the machining precision is ensured.
According to the connecting tool, the two half-shaped gears are assembled into the full-circle large gear, the original unstable half-circle structure is changed into the full-circle structure, and meanwhile, the assembled two half-shaped gears are symmetrically arranged, so that the unbalanced load problem in the machining process is solved, the machining process is stable, the machining precision is guaranteed, and the two half-shaped gears are machined together, so that the machining efficiency is effectively improved.
The invention also develops a special centering mechanism arranged on the cutter rest of the gear hobbing machine, ensures the accurate position of the disc milling cutter on the cutter rest, leads the symmetrical center surface of the disc milling cutter to pass through the rotation center of the machined gear, and fully ensures the machining precision.
Drawings
FIG. 1 is a schematic diagram of a combination gear;
FIG. 2 is a schematic view of a single segment tooth block;
FIG. 3 is a schematic diagram of a gantry milling rough machining tooth slot reference;
FIG. 4 is a reference schematic diagram of a planer milling semi-finished tooth slot;
FIG. 5 is a schematic view of a boring machine table rotating machining tooth slot;
FIG. 6 is a schematic diagram of a split full circular gear;
FIG. 7 is a schematic view of a coupling tool, FIG. 7 (a) is a partial view of the coupling tool and hub screw connection, and FIG. 7 (b) is a schematic view of a hole site on the connection face of the coupling tool;
Fig. 8 is a schematic diagram of disc cutter alignment using a dedicated centering mechanism, and fig. 8 (a) and 8 (b) are schematic diagrams of different views, respectively.
The tool comprises a gear block with an arc section, a hub, a central tooth slot, a balance, a connecting tool, a tool rest, a base, a telescopic rod, a 9V-shaped positioning block, a disc milling cutter and a tool setting reference surface.
Detailed Description
The invention will now be described in further detail with reference to the drawings and to specific examples.
The invention provides a processing method of a large-diameter multi-section combined gear, which is mainly suitable for a large-diameter multi-section combined gear with a central angle not larger than 180 degrees.
In the following embodiment, the processing method of the present invention is described in detail with reference to the large-diameter multi-section combined gear shown in fig. 1, wherein the combined gear is formed by combining 6 sections of arc section tooth blocks 1 with the same length, a hub 2 and the like, the tooth shape of each arc section tooth block 1 is standard straight teeth, the diameter of the gear is about phi 16 meters, the gear precision is of the grade GB/T10095-8, as shown in fig. 2, the length center of each arc section tooth block 1 is a tooth slot, namely a central tooth slot 3 in the figure, and the two end faces of the length are half tooth slots.
The machining method comprises the steps of firstly adopting a high-precision numerical control machining center and matching with a finger-shaped milling cutter to carry out rough machining and semi-finish machining on the arc-segment tooth blocks 1, carrying out intermediate alternate arrangement and ageing treatment to eliminate stress, then assembling a plurality of arc-segment tooth blocks 1 into two half-shaped gears, assembling the two half-shaped gears with weaker rigidity into a full circle gear through a connecting tool 5, and finally adopting a large vertical lathe and a large gear hobbing machine to carry out finish machining, wherein the gear hobbing is directly carried out after finish milling, and the specific process is as follows.
1. Tooth profile of arc segment tooth block 1 is thick processing and semi-finishing.
1) Rough machining of tooth shapes of the arc section tooth blocks 1.
Firstly, rough machining of the shape of the arc section tooth block 1.
In a numerical control planer boring and milling machine, roughly machining each part of the large surface and the inner circle and the outer circle of the outline thickness and the length end in a programming way; and then carrying out a tempering process to ensure the hardness requirement of the drawing.
And secondly, semi-finishing the appearance of the arc section tooth block 1.
In a numerical control planer boring and milling machine, the outline thickness and the length end large surface and the inner and outer circle parts are processed in a programming semi-finishing mode.
And thirdly, milling a reference tooth slot by the arc section tooth block 1, as shown in fig. 3.
In a numerical control planer boring and milling machine, the center line and the end face of an arc section tooth block 1 are aligned, leveled and pressed, a machine tool finds the rotation center of a part by taking an outer circle as a reference, the two ends of the length are centered, a tooth slot 3 of the length center is taken as a tooth slot of 0 bit, the groove shape of each tooth is milled by programming, the allowance 4 is uniformly reserved according to the allowance requirement, the machining depth is 5mm, and the groove shape is taken as a reference groove shape, so that the boring machine can find the right-angle cutter for machining conveniently.
Fourth step, the tooth slot is roughly milled by the arc segment tooth block 1, and refer to fig. 5.
The arc segment tooth block 1 is horizontally placed on a boring machine rotary table, wherein in the figure, O1 is the center of a gear, O2 is the center of the boring machine rotary table, and in order to facilitate alignment, the center line of a part and the center line of the rotary table are aligned in a parallel state. The boring machine spindle is provided with a finger-shaped milling cutter, namely, each tooth groove can be processed by combining translation of the boring shaft and aligning the center of each tooth groove to be consistent with the center of the spindle through angles of a rotary workbench, namely, theta, 2 theta, 3 theta, 4 theta and 5 theta, wherein the included angle theta=360 degrees/Z of each tooth groove is the number of whole circle teeth.
2) And (3) after processing, artificial aging, namely, feeding the steel into a heat treatment furnace, controlling heating temperature rise, heat preservation time and cooling speed, and eliminating processing stress.
3) Semi-finishing the tooth shape of the arc section tooth block 1.
Firstly, semi-finishing the appearance of the arc section tooth block 1.
In a numerical control planer boring and milling machine, the outline thickness and the length end large surface and the inner and outer circle parts are processed in a programming semi-finishing mode.
Step two, milling a reference tooth groove by the arc segment tooth block 1, referring to fig. 4, in the method, the third step is the same as the rough machining, in a numerical control planer boring and milling machine, aligning and leveling the center line and the end face of the arc segment tooth block 1, compacting, finding the rotation center of a part by taking the outer circle as a reference, centering the two ends of the length, taking the tooth groove 3 of the length center as a tooth groove of 0 bit, milling the groove shape of each tooth in a programming way, uniformly keeping a margin 4 according to the requirement of the allowance, and taking the groove shape as a reference groove shape, so that the boring machine can conveniently find the right-angle cutter for machining.
The third step, half finish milling tooth grooves of the arc section tooth block 1, referring to fig. 5, the method is the same as the fourth step of rough machining, the arc section tooth block 1 is horizontally placed on a boring machine rotary table, O1 is the center of a gear, O2 is the center of the boring machine rotary table, in order to facilitate alignment of the center line of a part and the center line of the rotary table to be in a parallel state, a finger milling cutter is assembled on a boring machine main shaft, and each tooth groove can be machined by combining translation of the boring shaft and alignment of the center of each tooth groove with the center of the main shaft. The included angle θ=360°/Z for each tooth slot, Z-full circle tooth count.
2. And assembling the arc section tooth block 1.
After semi-finishing is finished, a plurality of arc segment tooth blocks 1 are assembled into a semi-shaped gear according to the form of a combined gear shown in fig. 1 (the semi-shaped gear refers to the assembled combined gear which is not finished with tooth-shaped finishing and subsequent procedures), because the central angle of the semi-shaped gear is smaller than 180 degrees, deformation problems exist in independent machining, and meanwhile, when a vertical lathe and a gear hobbing machine are used for machining, semi-circles are difficult to align and measure, and the problem of unbalanced load during machining can also cause larger machining errors, two semi-shaped gears combined by the arc segment tooth blocks 1 and a hub 2 are of small semi-circular symmetrical structures, and when the combined gears are combined into a circle, larger gaps are formed at two positions of 180 degrees, the combined gears cannot be combined into a circle, the diameter size cannot be measured in vertical lathe machining, and the state of vertical lathe machining cannot be clamped during gear hobbing machine machining, and the precision of a final gear cannot be met.
Therefore, the connecting tool 5 is designed before finish machining, as shown in fig. 6-7, the notch parts at the two ends are complemented by the connecting tool 5, so that the two semi-shaped gears are assembled into the full circle gear, the original unstable small semi-circle structure is changed into the full circle structure, the assembled two semi-shaped gears are symmetrically arranged, the unbalanced load problem in the turning and gear milling machining processes is solved, meanwhile, the two semi-shaped gears are machined together, the machining process is stable, the diameter size of the gear is convenient to measure and control, the machining precision is guaranteed, and the machining efficiency is improved.
During assembly, the circle centers of the two half-shaped gears are overlapped and the tooth parts are symmetrically arranged, the end faces of the two sides are respectively connected and fixed through the connecting tools 5, as shown in fig. 6, if the central angle of the half-shaped gears is smaller than 180 degrees, the two connecting tools 5 are respectively arranged at the gaps between the end faces of the two half-shaped gears and are connected with the hubs 2 on the two sides through screws, the two connecting tools 5 are identical in size and symmetrically arranged, the connecting tools 5 are designed to be just capable of filling the gaps, so that the two half-shaped gears are assembled into a full-circle gear with symmetrical tooth parts, and if the central angle of the half-shaped gears is equal to 180 degrees, the hubs 2 on the two sides are directly and fixedly connected to form the full-circle gear.
3. And (5) tooth profile finish machining of the full-circle gear.
The tooth profile finish machining of the whole round gear is carried out on a large vertical lathe and a large gear hobbing machine, and the tooth profile is ensured to meet the precision requirement after the machining is finished.
The invention provides a machining method for precisely cutting a gear by adopting a disc milling cutter 10 on a large gear hobbing machine, and because the disc milling cutter 10 is commonly used for roughly machining the gear tooth form, in order to ensure high-precision gear machining (8-level precision) in the invention, a special alignment scheme for the disc milling cutter 10 is designed, and the gear machining precision is ensured.
In order to ensure that the position of a disc milling cutter 10 on a cutter rest 6 is accurate, namely that the symmetrical center surface of the disc milling cutter 10 passes through the rotation center of a machined gear, the invention designs a special centering mechanism and the disc milling cutter 10 with a cutter aligning reference surface 11, as shown in fig. 8, the special centering mechanism is arranged on the cutter rest 6 of the gear hobbing machine, the special centering mechanism consists of a base 7, a telescopic rod 8 and a V-shaped positioning block 9, the cutter body of the disc milling cutter 10 is provided with the V-shaped cutter aligning reference surface 11, the included angle of the cutter aligning reference surface 11 is consistent with the included angle of the V-shaped positioning block 9, when the disc milling cutter is used, the center of a round gear is aligned with the center of the rotation workbench of the gear hobbing machine firstly, then the special centering mechanism is arranged at a set position on the cutter rest 6 of the gear hobbing machine, the disc milling cutter 10 is arranged, the telescopic rod 8 is adjusted to enable the V-shaped positioning block 9 to extend out to be contacted with the cutter aligning reference surface 11 of the disc milling cutter 10, a clearance between the cutter aligning reference surface 11 and the V-shaped positioning block 9 is checked by a clearance gauge, the clearance between the two sides is consistent by the clearance gauge, and the clearance between the cutter 10 is checked by the clearance gauge is checked, so that the center of the round gear is ensured to pass through the symmetrical center of the round gear, and the round gear is ensured to be centered.
In the above embodiment, the arc section tooth block 1 and the hub 2 are assembled together when the gear is precisely turned and precisely milled, so that the deformation of the arc section tooth block 1 which is separately processed and the installation error during assembly are avoided, and after the gear is precisely milled by the two half-shaped gears, the precision is detected on line, the 8-level precision requirement is met, and the design requirement and the assembly requirement of a drawing are met.
The processing method of the present invention has been described above with reference to specific embodiments, but the processing method of the present invention is not limited to processing the combined gear shown in fig. 1, and is also applicable to processing any large-diameter multi-segment combined gear similar to the above-described gear form.
In general, the invention provides a set of large-diameter multi-section combined gear processing general scheme, which has the following characteristics:
1) Firstly, the split is processed independently, then the mixture is spliced into a whole circle for finish machining, the independent processing deformation and assembly errors are avoided;
2) The gear segment 1 of the arc section is subjected to quenching and tempering treatment, and then is subjected to outer contour machining and gear cutting for three times alternately, wherein the machining allowance of the first gear cutting is 10mm (single block of rough machined tooth form), the machining allowance of the second gear cutting is 5mm (single block of semi-finished tooth form), and the machining is performed for the third time (combined whole circle of finished tooth form);
3) An artificial aging treatment is arranged after the first gear cutting to eliminate internal stress;
4) After the second gear cutting processing, the multiple arc-segment gear blocks 1 are assembled into two half-shaped gears, and the two half-shaped gears are assembled into a full circle gear with symmetrical gear parts through a connecting tool 5;
5) And (5) carrying out finish turning and finish milling on the large vertical lathe and a large gear hobbing machine.
The invention also provides a method for rough machining and semi-finishing the tooth shape of the arc segment tooth block 1, innovates a method for centering, uniformly setting and controlling deformation of the rough machining tooth shape of the arc segment tooth block 1 by adopting a boring and milling machine, realizes the whole circle machining of the combined gear by adopting a connecting tool 5, ensures the precision of milling teeth by adopting a special centering mechanism, provides a high-efficiency and high-precision machining method for machining the large-diameter multi-section combined gear, and is proposed according to the prior equipment and production capacity without improving or upgrading equipment, thereby reducing the production cost and improving the production efficiency.
The present invention is not limited to the preferred embodiments, and the present invention is described above in any way, but is not limited to the preferred embodiments, and any person skilled in the art will appreciate that the present invention is not limited to the embodiments described above, while the above disclosure is directed to various equivalent embodiments, which are capable of being modified or altered in some ways, any simple modification, equivalent variations and alterations made to the above embodiments according to the technical principles of the present invention will still fall within the scope of the technical aspects of the present invention.
Claims (10)
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| CN108637613A (en) * | 2018-03-24 | 2018-10-12 | 徐州迈斯特机械科技有限公司 | A kind of method for processing sector gear |
| CN111185733A (en) * | 2018-11-14 | 2020-05-22 | 衡山同远机械有限公司 | Method for machining gear with large modulus and few teeth |
| CN110193708A (en) * | 2019-05-31 | 2019-09-03 | 中国电子科技集团公司第三十九研究所 | Super-large diameter multisection type ring gear machining method |
| CN110961876A (en) * | 2020-01-03 | 2020-04-07 | 重庆齿轮箱有限责任公司 | Machining method of two half type gear rings |
| CN113732637A (en) * | 2021-09-26 | 2021-12-03 | 中信重工机械股份有限公司 | Large-diameter split type thin-wall gear ring machining method |
| CN113814680A (en) * | 2021-09-26 | 2021-12-21 | 中信重工机械股份有限公司 | Manufacturing method of asymmetric large-modulus single-web thin-wall split large gear |
| CN114505658A (en) * | 2022-02-23 | 2022-05-17 | 中实洛阳重型机械有限公司 | Machining method of sectional gear ring |
| CN116493888A (en) * | 2023-06-28 | 2023-07-28 | 沈阳汉威机械制造有限公司 | Processing technology of high-precision multi-section-face hard-tooth large gear ring and large gear ring |
| CN117948404A (en) * | 2023-12-29 | 2024-04-30 | 常熟市神力机械制造有限责任公司 | Combined gear ring and processing method thereof |
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