Damage to the non-standard gears on the imported equipment requires repairs. This gear is usually machined from imported gear parts or specially manufactured tools. Both methods are not economical and time consuming. The best choice is to use non-standard gears with existing machine tools and tools. Yuan Zhejun et al., "Method of Processing Non-Standard Gears with Standard Tools" (published in the 1st issue of "Machine" magazine, 1979) proposes that non-standard gears be machined on a Magg type gear cutting machine using a rack cutter with adjustable pitch. , but this machine is rare in the factory. The method proposed in this paper can be implemented in a general factory. The gear grinding machine is a relatively common device in the factory. The principle of generating grinding teeth is the same as the principle of machining gears with a rack cutter. It can be used for processing any non-standard modulus and non-standard pressure angle gears. However, gears with very small modulus can be ground directly on the gear grinding machine. Slightly larger modulus gears are not suitable and require a pre-machined profile. It is very difficult to machine accurate non-standard gears with standard tools (rollers, pinion cutters). If rolling and inserting are used as gear pre-processing steps, the remaining amount is increased and the correct tooth shape is finally ground by the gear grinding machine. Although the machining efficiency is low, the accuracy of the gear can be guaranteed. As we all know, the basic condition for the meshing of the involute gear with the rack (gear) is that the pitch of the base circle must be equal, and the same applies to the hob and pinion cutter when machining the gear. That is, Pb0=Pb1 (1) or pm0cosa00=pm1cosa1 where: m0,m1——modulus of tool and gear, mm Pb0,Pb1—base section a0,a1 of tool and gear—tooth angle and gear of tool Pressure angle on the graduation circle, (°) As long as the product of the tool's module and the tooth angle is close to or equal to the product of the module and the pressure angle of the gear being cut, the tool can be used to machine the gear. If the base difference between the two is less than the tolerance range, the gear can be used directly. If the error is too large, it is necessary to leave enough margin to use the grinding teeth to get the correct gear. When cutting the teeth, the normal length L of the test is usually used to control the thickness of the teeth, and the grinding allowance must be considered to eliminate the base section error, which is larger than usual. Because the length of the common normal is actually several base segments plus a base circle tooth thickness L = (n-1) Pb1 + Sb1 (2) where: Sb1 - base circle tooth thickness, mm n - length of common normal across teeth The increase is ∆L=(n-1)∆Pb1 where: ∆Pb1—base pitch difference between tool and gear, mm Finally check the tooth depth: the tooth thickness on the gear pitch circle should be equal to the tool The width of the slot in the pitch line. That is, S'=r'[s/r+2(inva1-inva0)] tool shift value zm0=(S-S')/(2tga0) root radius rf=r'-zm0-h"m0 Medium: r - gear sub-circle radius, mm r' - gear pitch circle radius, mm S - gear sub-circle tooth thickness, mm z - shift factor h" - gear root height coefficient (3) The radius of the tooth root circle calculated is similar to the gear drawing value. If you use a slotting knife, the analytical calculation method is similar. For helical gears, the above method can also be used to realize standard cutter machining of non-standard gears. Only in the differential gear ratio adjustment formula, the modulus value should be the workpiece modulus m1 instead of the tool modulus m0. The calculation example is provided with a non-standard gear, radial pitch DP=4; pressure angle a1=15°; number of teeth Z=40, and the method of machining is determined. By comparison, with the m = 6.5, a0 = 20 ° hob processing, the base of the two are the closest. Pb0=3.1416×6.5×cos20°=19.189
Pb1=3.1416×6.35×cos15°=19.269
∆Pb1=-0.08 The actually machined gear ratio is smaller than the required gear base design, and the base circle is also smaller. The pitch circle diameter d'(mm) is d'=m0 Z=260. The grinding mill's normal normal length should be increased by one ∆L, that is, ∆L=(5-1)×0.08=0.32. Check tooth height. : S = 9.975; S' = 7.930; zm0 = 3.132; rf = 119.00, similar to the drawing requirement rf = 119.06. If the base section error is large, only enough margin is left for grinding. If there is a large difference, only special tools are manufactured.
Pb1=3.1416×6.35×cos15°=19.269
∆Pb1=-0.08 The actually machined gear ratio is smaller than the required gear base design, and the base circle is also smaller. The pitch circle diameter d'(mm) is d'=m0 Z=260. The grinding mill's normal normal length should be increased by one ∆L, that is, ∆L=(5-1)×0.08=0.32. Check tooth height. : S = 9.975; S' = 7.930; zm0 = 3.132; rf = 119.00, similar to the drawing requirement rf = 119.06. If the base section error is large, only enough margin is left for grinding. If there is a large difference, only special tools are manufactured.
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