磨齿加工误差补偿系统的设计与研究
|
摘要
磨齿是一种独特的切削方式，在理论上不论磨齿前的精度如何，齿轮硬度多高，都可以最大地提高齿形精度。然而，由于多种因素的影响，存在加工误差种类复杂、效率低下的问题。
本文综合运用了齿轮啮合理论，并以磨齿加工为例，系统地研究了与渐开线性质有关的齿轮加工误差产生的啮合机理，并将其概括为传动误差、回转轴相对位置误差及刀具误差。上述分析为齿轮加工误差补偿的理论研究奠定了必要的理论基础。
基于上述理论研究，结合国内外磨齿机的发展动态，分析了对磨齿机进行数控改装的可能性与必要性。并以Y7125磨齿机为例，设计了总体改装方案，在此改装系统中，本文着重研究了以离线测得的左右齿廓齿距累积误差为补偿控制对象，以计算机为控制单元，步进电机为执行机构，并利用机床原展成链和分齿链这一误差补偿系统。本文所设计的补偿系统不仅为量大面广的旧磨齿机的改造提供了机电一体化的有效途径，同时，对大型齿轮、硬齿面齿轮及各种齿轮加工刀具的加工具有特殊重要的意义。
在软件的设计方面，本文采用了建立在AutoCAD平台上的具有强大绘图功能的VBA语言。以VBA开发了Y7125磨齿机展成传动链的运动分析与动态仿真，并对磨齿加工误差补偿系统的模型建立、补偿算法进行了深入地研究。
In theory, gear-grinding is a kind of particular cutting method and can improve the dentiform precision of gear furthest regardless of the precision and hardness before the grinding. But, there exists some problems such as complicated kinds of machining errors and low efficiency influenced by many kinds of factors.
The machining errors of gear that relate to the nature of involute are studied with gear engagement theory and combining grinding-machining in this paper and they are summarized as transmission errors, axle relative position errors and cutter errors. The essential theoretic-basis has been established by the above analyses in the face of theoretic-study of error-compensation caused in the gear-machining.
On the basis of the theoretical study, combining the developing condition with regard to gear grinder at home and abroad, the necessity and possibility of transformation on gear grinder with numerical control technology are discussed as well as the whole transformating scheme is designed. In this scheme , the paper studies the compensation - system of gear-grinding errors mainly. In this system, the accumulative errors of tooth pitch of the left and right sides are taken for controlling and compensating object, the computer is used as control unit, step motor as the acting part and the primary generating and graduated chains of the machine tool are used. The designed compensation system in this paper not only provides an effective approach of mecha-electrical
integration for transformation of old and wide-large gear grinder but also has special meaning with regard to the machining of large-type gear , hard-dentisurface gear and all kinds of machining-gear cutters.
With regard to software-design, VBA established on the plarform of AutoCAD and having strong drawing function are applied in this paper. The motion-analysis and dynamic-state-simulation of generating-transmitting train(Y7125~type gear-grinder) are developed and the model-building and compensation- arithmetic of compensation system of gear-grinding machining-error are studied in depth with VBA.
本文综合运用了齿轮啮合理论，并以磨齿加工为例，系统地研究了与渐开线性质有关的齿轮加工误差产生的啮合机理，并将其概括为传动误差、回转轴相对位置误差及刀具误差。上述分析为齿轮加工误差补偿的理论研究奠定了必要的理论基础。
基于上述理论研究，结合国内外磨齿机的发展动态，分析了对磨齿机进行数控改装的可能性与必要性。并以Y7125磨齿机为例，设计了总体改装方案，在此改装系统中，本文着重研究了以离线测得的左右齿廓齿距累积误差为补偿控制对象，以计算机为控制单元，步进电机为执行机构，并利用机床原展成链和分齿链这一误差补偿系统。本文所设计的补偿系统不仅为量大面广的旧磨齿机的改造提供了机电一体化的有效途径，同时，对大型齿轮、硬齿面齿轮及各种齿轮加工刀具的加工具有特殊重要的意义。
在软件的设计方面，本文采用了建立在AutoCAD平台上的具有强大绘图功能的VBA语言。以VBA开发了Y7125磨齿机展成传动链的运动分析与动态仿真，并对磨齿加工误差补偿系统的模型建立、补偿算法进行了深入地研究。
In theory, gear-grinding is a kind of particular cutting method and can improve the dentiform precision of gear furthest regardless of the precision and hardness before the grinding. But, there exists some problems such as complicated kinds of machining errors and low efficiency influenced by many kinds of factors.
The machining errors of gear that relate to the nature of involute are studied with gear engagement theory and combining grinding-machining in this paper and they are summarized as transmission errors, axle relative position errors and cutter errors. The essential theoretic-basis has been established by the above analyses in the face of theoretic-study of error-compensation caused in the gear-machining.
On the basis of the theoretical study, combining the developing condition with regard to gear grinder at home and abroad, the necessity and possibility of transformation on gear grinder with numerical control technology are discussed as well as the whole transformating scheme is designed. In this scheme , the paper studies the compensation - system of gear-grinding errors mainly. In this system, the accumulative errors of tooth pitch of the left and right sides are taken for controlling and compensating object, the computer is used as control unit, step motor as the acting part and the primary generating and graduated chains of the machine tool are used. The designed compensation system in this paper not only provides an effective approach of mecha-electrical
integration for transformation of old and wide-large gear grinder but also has special meaning with regard to the machining of large-type gear , hard-dentisurface gear and all kinds of machining-gear cutters.
With regard to software-design, VBA established on the plarform of AutoCAD and having strong drawing function are applied in this paper. The motion-analysis and dynamic-state-simulation of generating-transmitting train(Y7125~type gear-grinder) are developed and the model-building and compensation- arithmetic of compensation system of gear-grinding machining-error are studied in depth with VBA.
引文
[1]经以广主编，渐开线圆柱齿轮加工机理、诊断及消减，沈阳出版社，1992
[2]Jia, Y.F. Liu, C. P. Computer compensation for precision gear grinder. Proceedings of Manufacturing International'90 Part4: Advances in Material and Automation Mar 25-28 1990 pp77-80
[3][苏]φ·Л·李特文著，卢贤占等译，齿轮啮合原理，上海科学技术出版社，1984
[4]P.zheng, W. wang, X.D. shang and Y.G. jing. Gear Hobbbing Compensation Technology. ICPE'96 & 6th SJUT, China. 1996, 9
[5]王明侗编著，渐开线齿轮精度，机械工业出版社，1983，1
[6]清源计算机工作室，Matlab基础及应用，机械工业出版社，2000
[7]Lawrence Livermore National Laboratory, Energy and Technology Review, September, 1987
[8]薛文达、谢文和、张呈祥合编，传感器应用技术，东南大学出版社，1998，12
[9]王立鼎，在用分度盘分度的磨齿机上被磨齿轮周节精度的研究，磨床与磨削，1981(3) p35-41
[10]韩念堔，电致伸缩微进给系统的设计和实验研究，太原理工大学硕士学位论文，2000
[11]罗国鑫，渐开线圆柱齿轮的磨齿加工，磨床与磨削，1985(2)p51-55
[12]袁哲俊、刘华明、唐宜胜合编，齿轮刀具设计(上册)，新时代出版社，1983
[13]上海机床厂技术情报室，磨齿加工基本知识，磨床与磨削，1974(6) p2-196
[14]陈超常，磨齿工艺与磨齿机，磨床与磨削，1991(4) p7-13
[15]罗国鑫，我国磨齿机发展的回顾和启迪，磨床与磨削，1990(4)
p17-18
[16]柏鸿文，80年代国外数控磨齿机的发展概况，磨床与磨削，1994(2) p3-9
[17]沈钟，从北京CIMT'93看国外磨齿技术的新进展，磨床与磨削，1993(4) p23-25
[18]柏鸿文，国外磨齿机的现状及发展趋势，磨床与磨削，1990(3) p17-21
[19]Siehart Lenz and Matthias Hoehnke, Berlin, Germany, optimization of Generating Pressure Angle for Gear Grinding by the Generating Process. European Produdcdtion Engineering 16(1992)3 pp49-52
[20]秦川机床厂“七·二一”工人大学、西安交通大学机制教研室《磨齿工作原理》编写组，磨齿工作原理，机械工业出版社，1975
[21]王鸿钰，步进电机控制技术入门，同济大学出版社，1990，9
[22]安建伟，磨齿机模糊变频调速系统的实验研究，太原理工大学硕士学位论文，2000
[23]贾云福，电致伸缩在磨齿机床上的应用，大连理工大学博士论文，1989
[24]秦川机床厂，Y7125磨齿机机床使用说明书
[25]张国宝编著，AutoCAD2000 VBA开发技术，清华大学出版社，1999
[26]Guo, Wenliang; Ya, Gang Error analysis and compensation of precision gear grinding. International Symposium on Test and Measurement, Proceedings Jun 1-4 1997 1997 International Academic Publishers p630-632
[27]Guo, Wenliang; Zheng, Xiaohua; Han, Nianchen Method of measuring system errors for gear grinding machine. International Symposium on Test and Measurement, Proceedings Jun 1-4 1997 1997
International Academic Publishers p655-658
[28] F. L. Litvin*, I. H. Seol (USA) , Computerized determination of gear tooth surface as envelope to two parameter family of surfaces. Computer methods in applied mechanics and engineering. 138(1996) pp213-215
[29] Xiao Ben Xian, The Main Control Mode and Fuzzy Control Strategy of CNC System for Gear Hobbing and Grinding Machine. Proceedings of IEEE International Conference on Industrial Technology, 1996 pp643-646
[30] Fradkin, E. I. ;Kolobanov, M. V. ;Vereina, L. I. The dependence of the gear wheel pitch errors on the accuracy of adjustment of the gear-grinding machine index change gear train. Pysics of Metals and Metallography v 798 1995 pp43
[31] Guo, Yinbiao;zhang, Jisheng|Wang, Hongjian Research on CNC indexing and amending for large plane grinding wheel gear grinders. Journal of Fire Sciences 13 4 Jul-Aug 1995 Technomic Publ Co Inc P29
[32] 江钧、许子凡，《3D Studio Max入门与提高》人民邮电出版社, 1999
[2]Jia, Y.F. Liu, C. P. Computer compensation for precision gear grinder. Proceedings of Manufacturing International'90 Part4: Advances in Material and Automation Mar 25-28 1990 pp77-80
[3][苏]φ·Л·李特文著，卢贤占等译，齿轮啮合原理，上海科学技术出版社，1984
[4]P.zheng, W. wang, X.D. shang and Y.G. jing. Gear Hobbbing Compensation Technology. ICPE'96 & 6th SJUT, China. 1996, 9
[5]王明侗编著，渐开线齿轮精度，机械工业出版社，1983，1
[6]清源计算机工作室，Matlab基础及应用，机械工业出版社，2000
[7]Lawrence Livermore National Laboratory, Energy and Technology Review, September, 1987
[8]薛文达、谢文和、张呈祥合编，传感器应用技术，东南大学出版社，1998，12
[9]王立鼎，在用分度盘分度的磨齿机上被磨齿轮周节精度的研究，磨床与磨削，1981(3) p35-41
[10]韩念堔，电致伸缩微进给系统的设计和实验研究，太原理工大学硕士学位论文，2000
[11]罗国鑫，渐开线圆柱齿轮的磨齿加工，磨床与磨削，1985(2)p51-55
[12]袁哲俊、刘华明、唐宜胜合编，齿轮刀具设计(上册)，新时代出版社，1983
[13]上海机床厂技术情报室，磨齿加工基本知识，磨床与磨削，1974(6) p2-196
[14]陈超常，磨齿工艺与磨齿机，磨床与磨削，1991(4) p7-13
[15]罗国鑫，我国磨齿机发展的回顾和启迪，磨床与磨削，1990(4)
p17-18
[16]柏鸿文，80年代国外数控磨齿机的发展概况，磨床与磨削，1994(2) p3-9
[17]沈钟，从北京CIMT'93看国外磨齿技术的新进展，磨床与磨削，1993(4) p23-25
[18]柏鸿文，国外磨齿机的现状及发展趋势，磨床与磨削，1990(3) p17-21
[19]Siehart Lenz and Matthias Hoehnke, Berlin, Germany, optimization of Generating Pressure Angle for Gear Grinding by the Generating Process. European Produdcdtion Engineering 16(1992)3 pp49-52
[20]秦川机床厂“七·二一”工人大学、西安交通大学机制教研室《磨齿工作原理》编写组，磨齿工作原理，机械工业出版社，1975
[21]王鸿钰，步进电机控制技术入门，同济大学出版社，1990，9
[22]安建伟，磨齿机模糊变频调速系统的实验研究，太原理工大学硕士学位论文，2000
[23]贾云福，电致伸缩在磨齿机床上的应用，大连理工大学博士论文，1989
[24]秦川机床厂，Y7125磨齿机机床使用说明书
[25]张国宝编著，AutoCAD2000 VBA开发技术，清华大学出版社，1999
[26]Guo, Wenliang; Ya, Gang Error analysis and compensation of precision gear grinding. International Symposium on Test and Measurement, Proceedings Jun 1-4 1997 1997 International Academic Publishers p630-632
[27]Guo, Wenliang; Zheng, Xiaohua; Han, Nianchen Method of measuring system errors for gear grinding machine. International Symposium on Test and Measurement, Proceedings Jun 1-4 1997 1997
International Academic Publishers p655-658
[28] F. L. Litvin*, I. H. Seol (USA) , Computerized determination of gear tooth surface as envelope to two parameter family of surfaces. Computer methods in applied mechanics and engineering. 138(1996) pp213-215
[29] Xiao Ben Xian, The Main Control Mode and Fuzzy Control Strategy of CNC System for Gear Hobbing and Grinding Machine. Proceedings of IEEE International Conference on Industrial Technology, 1996 pp643-646
[30] Fradkin, E. I. ;Kolobanov, M. V. ;Vereina, L. I. The dependence of the gear wheel pitch errors on the accuracy of adjustment of the gear-grinding machine index change gear train. Pysics of Metals and Metallography v 798 1995 pp43
[31] Guo, Yinbiao;zhang, Jisheng|Wang, Hongjian Research on CNC indexing and amending for large plane grinding wheel gear grinders. Journal of Fire Sciences 13 4 Jul-Aug 1995 Technomic Publ Co Inc P29
[32] 江钧、许子凡，《3D Studio Max入门与提高》人民邮电出版社, 1999