Investigation on Improving Manufacturing Precision of ZC1 Worm

Based on coordinate measrement of tooth surface of ZC1 worm, the deviation function for evaluating tooth surface is established. According to minimal zone principle, the profility of tooth surface of worm is evaluated. The machining errors of the worm are divided into setting error and adjusting error of the machine and tool. By error compensation, the setting error and adjusting error are corrected and the manufacturing precision of the worm is improved.     

Profile Precision of Hypoid Gears Controlled by Coordinate Measurements

The geometrical model of profile error is put forward to describe the tooth surface precision of hypoid gears. The influence of each machine tool setting error on profile error is investigated respectively, and the research of the associativity and compensativity among the machine tool errors are made. The setting errors of machine tool, the optimal modifying parameters and their value are got from the measurement coordinates of hypoid gear real tooth surface, and the adjusted manufacturing shows the geometrical precision of the tooth surface is improved effectively.     

Worm wheel grinding method of convex pitch line non-circular gear

To overcome the precision machining difficulty of non-circular gear, a convex pitch curve of non-circular gear and worm grinding method is presented. Firstly, worm wheel is reduced to rack cutter and a rack machining convex pitch curves of non-circular gears sport model is set up. Then based on the structure of CNC worm wheel grinding machine tools and machining principle, electronic gear box of machine tools is designed and active and following axes are planned. At the mean time, the synchronous coefficient of machine tools between synchronization is deduced by machining principle of equal arc-length, and interaction models of grinding are established. At last, the worm wheel manual presetting cutter methods with non-circular gear are given and worm grinding wheel mounting angle, axial position and axial location parameter can be adjusted along the gear.     

Study of Tooth Contact and Kinematic Precision on Cone-Generated Double Enveloping Worm Gearing

The tooth contact and kinematic precision of cone-generated double-enveloping worm gearing with machining and assembling errors have been investigated. The influence of different errors on driving quality has been discussed. The assembling method to reduce or eliminate the influences of machining errors on tooth contact and kinematic precision has been proposed.     

Effect of Tooth Modification on Double Enveloping Worm Gearing

A method of modifying the double enveloping worm gearing with developable tooth surface has been proposed to reduce the sensibility of the worm gearing to the manufacturing errors. The tooth contact and kinematic precision of the modified worm gearing with manufacturing errors has been investigated by the TCA method. The results show that by the modification, the edge contact resulting from the manufacturing errors is avoided or effectively relieved,and the kinematic error of the worm gearing is obviously reduced.     

A Solid Modeling and Geometric Analysis of Hourglass Worm Gearing

Based on the theory of conjugate surface and computer graphics, a solid modeling method of hourglass worm gearing is presented. Assembly simulation of worm gearing is carried out, clearance and interference between meshing tooth surfaces are analyzed, and effects of machining and modification of assembling parameters on meshing and contact between tooth surfaces are investigated.     

On line tool breakage monitoring method based on power information and cross-correlation algorithm

In order to reliably monitor unexpected tool failure and prevent workpiece or machine tool from possible damages in batch machining, a tool breakage on-line monitoring method based on power information and cross-correlation algorithm is proposed. In this method, wavelet coefficients of spindle-power signal are used as the characteristic vector of machining information, and then the vector sequence extracted from a normal machining process via Mallat wavelet is defined as the reference template for monitoring cutting tool condition. In batch machining, real-time characteristic vector of the workpiece in machining process is extracted via an improved real-time wavelet algorithm. The correlation of two vector sub-sequences within a sampling time window, which is described by generalized cross-correlation coefficient, decreases apparently when the tool is broken. The generalized cross-correlation coefficient is defined as tool condition index (TCI), and tool breakage can be detected by monitoring the TCI with a threshold value. Experiments show that the method can accurately identify tool breakage failures in normal machining condition, and thus it is practical.     

A new determination method of tool step for 5 axis NC machining

The peculiar non linear error in the 5 axis NC machining is studied. An improved tool step determination method for the 5 axis NC machining is proposed, in which the non linear error is compensated. Both the arc chord error and the non linear error are considered when computing the tool step, and the comprehensive error is taken as the function of the tool path parameter. Due to the difficulty of gaining the derivative of this function and the tool step according to the prescribed tolerance, the secant method is improved to guarantee the real solution locating in the converging range which is adopted to compute the tool step. The implementing example shows that the proposed method can compensate the non linear error effectively with meeting the prescribed tolerance. The exact tool step can be gotten efficiently with the improved secant method.     

The machine setting reverse method of spiral bevel gear

The profile error correction of spiral bevel gears is difficult. To solve this problem, the inspected method of spiral bevel gears tooth surface is studied in 3906 gear measuring center. The grids of tooth surface is measured by measurement software. Taking reference tooth surface as the goal, a method of machine setting reverse using approximation algorithms is proposed, and a mathematical model is build. At last, a reverse example based on grinded spiral gear is given. The result shows that the cutting machine setting of bevel gear tooth surface can be exactly calculated.     

Algorithm of Cutter Machining Position during Numerical Controlled Last Carving

Numerical control last making machine is a machine that is used to process shoe last. A new principle of numerical control machining shoe last is put forward aiming at the deficiency of current carving last system. On the basis of the principle, the algorithm of cutter machining position during numerical controlled carving last is analyzed in detail. The complex problem of the calculation of cutter machining positiion is resolved by applying spherical milling cutter that is often used in machining free_curve surface today and taking account of practical situation of the shoe last_making machine. At the same time, the calculation of cutter machining position is realized by program using Visual C++6.0. As a result, the calculation time of cutter machining position is reduced greatly and the efficiency of design is improved. Moreover, the process of carving last is agile and precision of carving last is ensured.     

Analysis on Oylindrical Worm in Traction Machine and Modifications

Cone enveloping cylindrical worm in traction machine as instance, theoretical analysis on cylindrical worm transmission has been theoretically analyzed, and efficiency test and load capability test of traction machine with YJ240 cylindrical worm have been done on open power gear experimental instrument. According to the experimental data, it indicates cylindrical worm have some weaknesses on load capability, efficiency, adjustment possibility of tooth backlash and so on. Therefore, on purpose of improving integral performance of traction machine, face worm with variable tooth thickness may be used as primary drive mechanism in traction machine instead of cylindrical worm.     

Accurate mathematical models for relief grinding of gear hob cutters

A mathematical model for accurate relief grinding of gear hob cutters along radial directions is presented based on the analysis of grinding geometry. Both the design and manufacturing models of gear hob cutters are carefully derived and presented. By employing the plane envelope theory, the reference contour of the grinding wheel is determined in order to attain the design tool profile precisely. The tooth profile error model after regrinding is also given to confirm the grinding parameters. The model provides accurate solutions for both the tool profile and the sectional contour of the grinding wheel. It is simple and straightforward and can be used to produce high precision hob cutters systematically. Two numerical examples are presented to illustrate the effectiveness of the proposed method. The model computing results indicate that the proposed method is practical, precise and reliable. The method provides valuable reference for the design and machining of hob cutters.     

Approaches to enhance power density of gearboxes for wind turbines

Based on pitting strength, some approaches to enhance power density of gearboxes for wind turbines are discussed. The calculation load is greatly reduced by power division. Allowable stress numbers are effectively increased by improving property of quality materials, precision heat treatment or shot peening. Load capacities can be also obviously enhanced by improving the tooth shape of morphology optimization of tooth root, tooth correction or superfinishing of tooth surface. The center distance is effectively decreased by minishing minimum allowable safety factor or enlarging face width. The power density of gearbox can be further improved by means of structure optimization of planet carrier or uniform load of planetary gear transmission.     

Bending Stress Analysis on Backlash Adjustable Worm Transmission

The full name of variable tooth thickness plane worm gear transmission is. Backlash adjustable plane worm gear with variable tooth thickness enveloping worm transmission, which is a new kind of accurate power transmission that is intervenient between traditional motion transmission and power transmission. Tooth surface equations of the variable tooth thickness plane worm gear transmission are deduced based on the theory of engagement. Basing on the result, the authors create a finite analysis model of backlash adjustable variable tooth thickness plane enveloping worm with perfect tooth shape by using I-DEAS software, and then has done finite element analysis of backlash adjustable variable tooth thickness plane enveloping worm transmission. Finally, the author drew a conclusion about distribution of principal stress and load distribution between teeth, which offer some references for strength and performance analysis of worm transmission.     

THE NEW SECTION PLANE OF NORMAL CYLIDRICAL WORM TOOTH FLAND ERROR ON THREE COORDINATE MEASURING MACHINE

The concept of "New Section Plane" has been proposed when the tooth flank error of normal cylidrical worm is measured on the three coordinate measuring machine .and it has been compared in many respects with the general" First Section Plane". It has been pointed out that "The New Section Plane" is superior to "The First Section Plane     

The Geometric precision and Performance Analysis for machining Surface based on Fractals

A new analysis method for machining surface profile error is presented in this paper.The linear regression and nonlinear regression are first applied respectively,and then the Weierstrass Mandebrot fractal function is used to obtain the fractal parameters of machining profiles.A minimal parameter set which depicts the machining surface geometric precision is set up,and the surface profile can be reconstructed using these parameters,and an analysis method for part performance and its tolerance structure is proposed.Examples are provided to illustrate the method is feasible and effective.     

Study of Modern Applied Technology for Design and Manufacture of Spiral Bevel and Hypoid Gears

A new method of computing the cutter specifications and machine settings for the manufacture of spiral bevel and hypoid gears is studied. And a software system which includes the program models of new and old methods is developed. The system can perform the computations such as blank dimensions,cutting and grinding settings,tooth contact analysis and under cut check of SGM,SFM,SGT,SFT,HGM,HFM,HGT,HFT cutting methods. The new method can allow the user to give the position and length of contact pattern,the direction of contact path and the relative anglar acceleration. The system can be easily operated.     

元动作装配单元误差传递模型及有效路径求解方法

在对机械产品进行"功能-运动-动作"结构化分解的基础上,将影响元动作装配单元装配精度的误差源分为零部件的形状误差、位置误差、装配位置误差和运动误差等四类误差源。引入误差链接模型作为元动作装配单元误差关联关系的基本封装单元,构建结构化误差关联模型——链接网络和链接矩阵,形象描述误差间的耦合嵌套关系。提出基于误差链接模型的装配误差传递路径求解方法,用老鼠迷宫算法搜索所有可能的误差传递路径,以装配精度最高作为判别依据,得到各误差分量的有效传递路径。以蜗杆转动元动作装配单元蜗杆轴线平行度误差有效传递路径为目标,对上述方法进行验证,结果表明该方法能够高效地搜索到所有误差传递路径,并快速获得有效传递路径。该方法的提出为整机装配过程质量预测与控制提供了理论依据。     

Constant Scallop-height tool-path Planning for Surface Interpolation and the Evaluation of Errors

The calculative precision of the cutting breadth has a significant effect on the machining precision and the machining efficiency for free-form surface machining. For traditional arithmetic, there are two oppositional approaches to calculate the path interval. One approach is very simple, but its veracity is not enough for complex surface. The other approach is very complicated, so its calculative efficiency is low. A new approach is presented to calculate the path interval. A spline of circle is adopted to approach the transversal of surface. Then the arithmetic based on the spline is proposed to calculate the path interval. In the proposed methodology, the calculative efficiency is fully improved on the condition of meeting the need of machining precision. Furthermore, the algorithm''s time needed by calculating path interval is steady. So it is suitable for periodic interpolation. Two study cases verify the applicability of this new approach of Constant Scallop-height tool-path planning.     

New Method of Machining Internal Spiral Groove of a Big Lift Angle

There exists muchinterference in machining internal spiral groove with big lift angle and small size, whichis a difficult problem. The design and calculation of tool section is analyzed in this paper while differentcutters are utilized to machine the groove when the tool axis is parallel or skew to that of the work piece. The approximating method of using circular-arc cutter is put forward, which is proved by the calculation and analysis to be a feasible method within range of the permissible error. The digital simulation of machining internal spiral groove which is finished by different methods, such as simulation of tool path, error analysis, verification of the cutter design and so on, has been done through typical software such as the Program files function of I-DEAS and the Manufacturing Module of UG.