数控机床机电一体化外文文献翻译.docx

数控机床机电一体化外文文献翻译.docx

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数控机床机电一体化外文文献翻译

数控机床机电一体化外文文献翻译

（含：

英文原文及中文译文）文献出处：

SafaviSM,MirianSS,AbedinzadehR,etal.UseofPLCmoduletocontrolarotarytabletocutspiralbevelgearwiththree-axisCNCmilling[J].InternationalJournalofAdvancedManufacturingTechnology,2010,49（9-12）:

1069-1077.

英文原文

UseofPLCmoduletocontrolarotarytabletocutspiralbevelgearwith

three-axisCNCmilling

SafaviSM,MirianSS,AbedinzadehR

Abstract

CNCmachiningnowadaysmakesmoreuseofHMechatronicsnincreasingly.Combiningnumericalcontrolwithmechanic,electric,anddataprocessingsystemscanleadtonewmethodsofproduction.Inrecentyears,thedevelopmentofCNChasmadeitpossibletoperformnonlinearcorrectionmotionsforthecuttingofspiralbevelgears.Inthispaper,weattempttomanufacturethespiralbevelgearusingathree-axisCNCmillingmachineinterfacedwithanadditionalPLCmodulebasedontraditionaldiscontinuousmulti-cuttingmethodaccomplishedbyusingauniversalmillingmachineinterfacedwithanindexingworkhead・Thisresearchconsistsof（a）geometricmodelingofthespiralbevelgear,（b）simulatingthetraditionalandournewnontraditionalmethodusingaCAD/CAEsystem,（c）processplanningforCNCmachiningandPLCProgramming,（d）experimentalcutswithathree-axisCNCmillingmachineweremadetodiscoverthevalidityofthepresentedmethod・TheresultsdemonstratethatinventedexperimentalcuttingmethodofSBGsnotonlyislessexpensivethanadvancedCNCmachiningbutalsoproducesgearsinashortertimeincomparisonwiththetraditionalcutting.Thereby,itisaneconomicalmethodinmanufacturingofSBGs.Keywords:

earmanufacturing・Spiralbevelgear.CAD/CAM/CAE・CNC・PLC・ACmotor・Inveiter・Proximitysensors・Photoelectricsensors・Rotaryencoder

1Introduction

Gearsareimportantprecisionmechanismsinthefieldofindustrialmachinery,usedtotransmitmechanicalpowerandmechanicalmovementbetweenparallelshafts,transversecrossesornon-intersectingshafts.Althoughsometimesinvisible,gearisstilloneofthemostimportantmechanicalcomponentsinourindustrialcivilization.Underawidevarietyofconditions,gearswilloperateatalmostunlimitedspeed・Thegearprocessingequipmentandprocessthathavebeendevelopedhavebeenveryadvancedandmature.Whetherformassproductionorsmallbatchproduction,theprocessofmachininggearsrequiresthefollowingfoursteps,whetherinasmallworkshoporabatchprocessingworkshop:

（1）Cutting

（2）cuttingteeth

（3）Heattreatment

（4）Grinding

Accordingtotheirtype,applicationrangeandstrengthandstiffnessrequirements,gearsareusuallymanufacturedthroughcasting,extrusion,forging,powdermetallurgy,injectionmoldingandhobbing.Inthisseriesofmachiningprocesses,thespiralbevelgearisthemostcomplicatedkindofgear,anditisusedtotransmitrotarymotionbetweentheangledhorizontalaxes.Inthedirectionofthetoothlength,thespiralbevelgearhasaradiallycurvedtoothprofilecurve・Thiskindofgearcanensureasmoothengagementwiththematinggears,mainlybecausetheyhaveacurvedprofilethatoutperformsthespurgears,sothattheywillcontactandengagemoreteethatthesametime.Thedesignandmanufactureofspiralbevelgearsisstillahottopicofresearch・Ithasbeenusedinhelicoptertransportgeartrains,motorcyclegearreducersandotherindustrialbranches・Formanufacturing,suchgearsareusuallymachinedfromaspecialmachine,suchasgearhobbingmachinesandformingmachines.Atpresent,specialCNCmachinetoolsbasedongeartoothprocessinghavebeenusedinindustrialpractice・Thismaybethereasonwhytherelatedliteratureongearprocessingisscarceinthepublicresearchfield.Recently,CNCmachinetoolsbasedongearmachininghavebeendevelopedandgraduallyusedinindustrialpractice・However,theirmotionstructureisstillintrinsicallydifferentfromindustrialCNCmillingmachines・Theformerisdesignedforaspecialtool.Previousresearchongearsmainlyrelatedtothedesignandanalysisofgears.Whilestudyingitsgeometricfeaturesanddesignparameters,TsaiandChinprovideamathematicalsurfacemodelforbevelgears（spurgears,helicalbevelgears）basedongeartransmissioninthetangentialdirectionandinvolutegeargeometry.Later,thisschemewascomparedwithA-daccaketal.andShunmuganetal.basedonaprecisionsphericalinvolutegearsurfacemodeltoarriveatacompletelydifferentmodel.Basedonthenominaldeviation,theaccuracy（comparedwiththeuseofaspecialmachinetoolingspiralbevelgear）hasbeenverified.

Forcrowngears,someconclusionsarefeasible・LitvinandKimproposedtheuseofFanChengmethodtoobtaininvolutecurvesbyimprovingthebasecircleofspurgears・Usingthemodifiedmeasuredvalueofthehelicalgeartransmissionerror,Umeyamadesignedastandardprofileonthepitchcircleanddesignedanimprovedprofileontheupperandlowersurfacesofthefacegear.Tamuraetal.developedapointcontactmodelforabevelgearwithaflattoothprofile・Thesestudiesarerelatedtothereturntoothprofileofthosespecialgearprocessingmachines（eggearhobbingmachines,formingmachines）speciallydesignedformachininggears・Suhetal.studiedthefeasibilityoftheprocessingmethodfortheengravingsurfaceofspiralbevelgears,

andverifiedthepossibilityofusingafour-axisCNCmillingmachinewithagyration-swingliftingplatformtogeneratemachiningtrajectories.Atthesametime,amodel-basedverificationmethodforhelicalbevelgearshasalsobeenproposed・

Inthispaper,wewilltryanewmachiningprocessforspiralbevelgears,usingathree-axismillingmachinewithaPLCmodulethatcanbeusedtocontroltheindextable.Obviously,theproductivityofthisprocessingmethodisnotasgoodasthatofspecial-puiposemachinetools.Inadditiontoproductivity,theadvantagesofthisprocessingmethodareasfollows:

（1）Traditionalprocessingmethodsrequirelargeinvestmentcoststoobtainvariousspecialmachinetools,andthetypesofgears,sizes,andgeometriesthatareselectedfortoolprocessingarealsoverylimited;

（2）Withthisnewprocessingmethod,varioustypesofgearscanbemachinedthroughindustrialthree-axisCNCmillingmachines;（3）Comparedwiththeuseofspecialpurposemachinetools,thismethodismoreeconomical.Adifferentfocusfrompreviousworkisthatinordertosimulatetheentireprocessandobtaintheprocessingparameters,anautomatedcomputermodelneedstobedeveloped・Allpreviousstudiesarecalculatingcomplexmathematicalequationsanddesigninggeometricmodels・Inviewoftheabove,ourfocusisontheexperimentaltestingofspiralbevelgearsratherthanthegeometricormathematicalmodelofhelicalbevelgears.ThisisthefirsttimetouseamechatronicmachineandaCNCmillingmachinetoprocessspecialgearsandevenamechanicalcomponent.

2Helicalbevelgeargeometry

Ingeneral,thegeometryofagearisgivenbyengineeringdrawings.Fordefiningitsgeometry,someparameters（mainparameters）arenecessary.Forthispurpose,weusethedriveelementdevelopmentsoftwarenamedHGearTraxntocalculatethesemainparameters・

Thedesignofspiralbevelgearsrequireshigh-precisionmathematicalcalculations,andtheproductionofsuchgeartransmissionsrequiresnotonlyhigh-qualityequipmentandmachinetoolsthatprocesssuchgeartrains,butalsotheneedtoextendappropriatemachineparametersettings.Althoughthissettingisnotuptostandard,italsoneedstobeabletoguaranteethe

Thedesignofeachconditionofthemotionrequirement（accordingtothegeometricparametersofthegeartransmissionandthedevelopmenttool）isdetermined・

3Processingspiralbevelgear

Fromthediscussionintheintroduction,weknowthatalltypesofgearscanbeprocessedtoachievealltherequiredspecifications,andtheprocessingmethodsforhigh-precisiongearsarestillexcellent.FormingMillingisthemostcommonmachiningprocedureformachininganytypeofgear.Thepropsusedallhavethesameshapeastheadjacentgearteethgap・Standardtoolsarecommonlyusedforformingandcuttinggears・IntheUnitedStates,eachofthesecuttersis8timestheoriginaldiameterandisusedtomachinethemulti-toothgearsindicatedonthestandardtable.GleasonCorporationisbasedonthegeneralconceptofbevelgearsdevelopedtocomplementtheprincipleofcrowngears:

largeandsmallmeshedgearscanbeconsideredseparatelyandsurfacehobbingisused・

FanChengscrowngearcanbeconsideredasaspecialhelicalgearwithahelixangleof90degrees・Therefore,thegenerictenn"geargear^emerged.Whenthematingfaceofthegeneratedlargeandsmallgearsisconjugated,considerationcanbegiventosupplementingtheconceptofvanishingcrowngears.Inpractice,theteethofthegearsmaydifferfromoneanotherinordertomatchthemismatchedtoothsurfaces・Therotationofthegearisreflectedbythecradlerotationonthegea匚

Toprocessspiralbevelgearswithathree-axisCNCmillingmachine,weshouldfirstenjoyprogramtestingoftheCAD/CAMsystem'sgeometrymodelingandsimulationmodule.UsecommercialsoftwareSolidworkstocreateCADmodelsandMSCs.VisualNASTRAN4Dsoftware（aCAEmechanicalmotionanalysissystemusinga3Dmodel）wasusedtosimulategearmachiningandanalyzetheresults・

Forthestructureofthemachinetool,itisobviousthatthehistoryoftherotarymotionoftheworkpieceonthespiralbevelgearCNCmachine

toolisnecessary.Basedontheanalysisofitscuttingperformance,throughaone-stepinstallation,thespiralbevelgearCNCmachiningcanatleastachievetherequirementsoffour-axiscontrol.