飞刀径向进给加工锅轮工作后角分析

为了避免飞刀径向进给加工蜗轮过程中可能出现的切削抗刀现象并保证蜗轮齿面的加工质量,必须使飞刀左右侧刃的实际工作后角不致过小。文中提出了考虑径向进给速度时飞刀左右侧刃工作后角的计算方法,实际算例验证了其正确性。     

带螺旋角双导程蜗轮滚刀齿距测量误差分析

双导程蜗轮滚刀在制造时,其左右侧导程应分别等于原工作蜗杆的左右导程,左右侧切削刃螺纹升角应分别等于原蜗杆的左右侧螺纹升角.由于刀具刃口方向螺旋角与刀具左右侧切削刃实际螺纹升角之间有一定的差别,此时刀具的前刀面与切削刃螺旋平面不垂直,从而引起刀具齿距测量误差.本文在制造带螺旋角双导程蜗轮滚刀时,通过刀具测量对螺旋角与实际...     

加工蜗轮飞刀实际工作后角的计算及应用

以加工“11头蜗轮飞刀”为例，阐述了加工大螺旋角蜗轮的工作后角计算方法，并用实例进行了验证。     

小螺旋升角蜗轮飞刀的改进

蜗轮齿形的加工,在机修行业一般是采用蜗轮飞刀,而蜗轮飞刀的设计均以蜗杆参数为依据。按常规的飞刀设计,只要蜗杆有一个参数(包括旋向)不同就要设计一把飞刀,但我们从长期的飞刀设计及蜗轮加工工作的实践中总结出来,对于一些螺旋升角λ_f小于8°的蜗轮飞刀,在设计上是可以改进的。常用的飞刀结构,是用一个带有5°斜面的拉销将刀头紧固在飞刀杆上(如图1),过去在设计螺旋升角小于5°的右旋飞刀时,很容易将刀头柄部平面与前刃面的夹角算错,从而使刀头成为废品,即使该夹角计算正确,也会因在加工时难以保证其精度而影响了蜗轮的齿形,所以在飞刀的设计、加工和安装等各方面,都存在着程度不同的问题和困难。     

飞刀加工蜗轮的切削干涉

文章对飞刀加工蜗轮过程中,飞刀实际切削后角的变化进行了分析,找出产生切削干涉的原因,并提出解决方法.     

单齿飞刀连续分度加工平面齿蜗轮方法的研究

针对单角度盘铣刀加工平面蜗轮效率低等缺点，提出了一种用单齿飞刀连续分度加工平面齿蜗轮的方法。单齿飞刀制造方便，加工过程简单，连续分度的加工效率比单齿分度高。建立了飞刀直刃运动数学模型，分析了飞刀切得的齿面与理论齿面之间的关系，提出了飞刀安装倾角的求解方法。对于高精度平面蜗轮制造，该方法具有很高的应用价值。     

问题解答

[问] 球面蜗轮采用双飞刀加工,它的齿形精度和实际齿厚是怎样控制的? (重庆矿山机器厂常光旭苏州纺织机械厂刘鲸) [答] 在没有球面蜗轮滚刀的情况下球面蜗轮采用双飞刀加工,是普遍的加工方法。双飞刀的安装角度,是利用球面蜗杆入口处的起角(蜗杆出口处称始角)设计的,如图1所示。所以蜗轮加工后齿侧表面的形状,不是蜗杆螺旋工作表面全民上的包络面如图2所示。要想达到“双接触线”的啮合要求,还     

飞刀加工蜗轮的切削螺旋角和切削抗刀

飞刀是指单齿法向飞刀,用这种飞刀加工蜗轮,一般分粗、精切齿两个工序。粗切齿时,飞刀齿对准工件中心,径向进给;精切齿时,调整机床中心距离符合要求,切向进给。用蜗轮飞刀切齿时,飞刀和工件的相对运动决定切削齿面螺旋角。此处所指的切削齿面螺旋角,不是公称的蜗轮分度圆的螺旋角,而是     

用靠模飞刀法加工蜗轮

用靠模飞刀法加工蜗轮在加工数量很少的蜗轮时，制造一把蜗轮滚刀往往很不经济，此时可采用单齿飞刀在滚床或铣床上加工蜗轮。所谓单齿飞刀，就是在刀杆上装一把刀头代替蜗轮滚刀的一个刀齿进行切削加工。用单齿飞刀加工蜗轮，一般是在带有切向刀架的滚齿机上进行。加工时...     

刃磨空间直线切削刃

我厂自行设计的阿基米德蜗轮飞刀如图1所示,它以φ30h6外圆、端面在飞刀刀杆上定位,以尺寸50mm一侧面确定其法向安装角。飞刀前刀面与水平面夹角为12°,两切削刃与分中线夹角均为19°53′6″±1′30″,对基准A对称度为0.025mm。顶刃、侧刃后角均为12°。如按通常方法磨削两侧刃,即将飞刀置于已找正好的双向正弦规上,用百分表找正,保证飞刀前刃面垂直于工作台平面及工     

刀具的数控刃磨加工方法

本文介绍了刀具各表面的数控刃磨加工工艺、刀位算法，并分析了加工过程中砂轮与刀具之间的轨迹干涉     

径向进给法滚削蜗轮齿侧棱面高度的计算方法

滚削蜗轮时 ,其齿侧面为滚刀切削刃在一系列不同位置的包络面 ,因而不可避免地要产生棱面。在以圆弧代替渐开线的基础上 ,导出了蜗轮齿侧棱面高度及数目的计算方法及影响他们的因素。其公式简单 ,结果也足够精确。     

基于线性插补加工零刃带螺旋回转面刀具的精度研究

针对多轴线性插补方法加工零刃带回转面刀具建立了刃带宽度误差的分析模型,兼顾分析了两个几何体——砂轮大圆和锥面,在工件表面按一定规律运动时对刀刃宽度的精度影响,给出了减小误差的方法。同时提出了刀刃节点交错的刀位(CL)轨迹计算原理,可以大大改善刀具加工工件的表面质量,此方法简单可靠,具有通用性。     

Investigation of cutting characteristics for worm machining on automatic lathe — Comparison of planetary milling and side milling

A worm and worm wheel gearing is widely used in a geared motor unit for the convenience and safety of an automobile. For mass production of a high quality worm, the current rolling process is substituted with the milling process. The milling process offers comparatively accurate machining quality and high production capacity for worm manufacturing. Moreover, since the milling process enables the integration of all operations of worm manufacturing on a CNC lathe, production efficiency can be remarkably improved. However, there are several important factors to be considered for producing high quality worms such as cutting force, tool-workpiece interference, and others. Planetary milling and side milling are generally applied to machine worms. In this study, the cutting characteristics of worm machining on an automatic lathe are investigated for two types of milling processes and those processes are compared with each other. A tool-tip trajectory model based on tool-workpiece interaction is proposed, and then tool-workpiece interference and cutting force are simulated with the model. The simulation results are verified through numerous experiments. The experimental results show the cutting characteristics of each milling process and the efficiency for mass production of a high quality worm. This paper was recommended for publication in revised form by Associate Editor Dae-Eun Kim     

Blend of sharpness and strength on a ball nose endmill geometry for high speed machining of Ti6Al4V

The applications of titanium alloys are increasingly common at marine, aerospace, bio-medical and precision engineering due to its high strength to weight ratio and high temperature-withstanding properties. However, whilst machining the titanium alloys using the solid carbide tools, even with application of high pressure coolant, reduced tool life was widely reported. The generation of high temperatures at the tool–work interface causes adhesion of work material on the cutting edges, and hence, shorter tool life was reported. In order to reduce the high tool–work interface temperature-positive rake angle, higher primary relief and higher secondary relief were configured on the ball nose endmill cutting edges. Despite of careful consideration of tool geometry, after an initial working period, the growth of flank wear accelerates the high cutting forces followed by work material adhesion on the cutting edges. Hence, it is important to blend the strength, sharpness, geometry and surface integrity on the cutting edges so that the ball nose endmill would exhibit an extended tool life. This paper illustrates the effect of ball nose endmill geometry on high speed machining of Ti6Al4V. Three different ball nose endmill geometries were configured, and high speed machining experiments were conducted to study the influence of cutting tool geometry on the metal cutting mechanism of Ti-6Al-4V alloy. The high speed machining results predominantly emphasize the significance of cutting edge features such as K-land, rake angle and cutting edge radius. The ball nose endmills featured with a short negative rake angle of value ?5° for 0.05～0.06 mm, i.e. K-land followed by positive rake angle of value 8°, has produced lower cutting forces signatures for Ti-6Al-4V alloy.     

圆弧齿圆柱蜗杆副轮齿强度分析

介绍圆弧齿圆柱蜗杆副齿廓啮合原理,齿形车削加工方法,建立起GB9147—88圆弧齿圆柱蜗杆副蜗轮、蜗杆的有限元计算模型。分析蜗轮蜗杆啮合过程中2个特殊承载位置应力与位移的变化,用动力学理论计算出蜗杆传动固有频率、临界转速,为试制GB9147—88圆弧圆柱蜗杆减速器提供合理而可靠的理论依据。     

研磨轮结构参数对工件加工精度的影响

通过建立研磨轮和工件的相对运动数学模型，得出研磨轮在工件上的切削运动轨迹方程，由此得到超精密平面研磨中，不同结构参数研磨轮的滑移轨迹长度，引入精度系数的概念，用于评价不同结构参数研磨轮对工件的加工效果，采用微粒金刚石研磨轮对单晶硅和压电陶瓷材料进行研磨实验的结果表明，使用设计合理的研磨轮可以提高研磨的加工精度。     

制造执行系统中刀具剩余磨损寿命预测的研究

以机械加工车间为背景,探讨了在CIMS环境下制造执行系统中刀具剩余磨损寿命的预测模式,推导了刀具磨损寿命计算公式中的系数表达形式,并提出了刀具磨损寿命预测在实际加工中的实现方式。     

平面二次包络环面蜗杆的一种新加工工艺及加工精度分析

介绍了一种新的加工平面二次包络环面蜗杆的工艺,对实现此新工艺的数控磨床的结构从原理上做了介绍,并在此基础上对加工环面包络蜗杆的产形面方程进行了推导,探讨了新工艺对环面包络蜗杆加工精度的影响。