超复杂分段曲面不完全设计和连续展成理论及环面蜗轮滚刀磨削技术研究

The toroidal worm gears are more conform to the lightweight developing trend of the gear industry because they have higher load capacity, less volume, higher efficiency, and longer life than the cylindrical worm gears. However, the manufacture of the toroidal worm hobs are very complicated and difficult because the bilateral blade curves of every cutting teeth of the hobs are all different with each other and so are the helix angles of each point of the curves on the hob's helicoids. The manufacture problem of the high precision and high efficiency of the hobs has not yet solved till now and the popularization and application of the toroidal worm gears are restricted. The incomplete design theory of the ultra-complex segmented surfaces of the discontinuous cutting teeth of different kinds of worm hobs is studied based on the generating theories of the ultra-complex helix surfaces of different kinds of worm hobs. The generating theory and method of the ultra-complex segmented surfaces are researched based the conjugate surface theory by using the simplest and the most efficient generating planar and conical surface. The continuous generating theory of the cutting teeth of different kinds of worm hobs is developed to make the widths of the cutting edges and the angles of the side relief surfaces of the cutting teeth fulfill the demand values and keep uniformity respectively. The grinding technology of the cutting teeth of the worm hobs is studied. By grinding the cutting teeth of worm hobs and measuring the widths of the cutting edges and the angles of the side relief surfaces, the feasibility and the validity of the theory and method are verified. These will provide the theoretical and practical technology basis for the improvement of the manufacturing level of the worm hobs and the quality of the toroidal worm gears.

与圆柱蜗杆传动比较，环面蜗杆传动承载能力强、体积小、传动效率高、使用寿命长等，符合齿轮行业轻量化的发展趋势。但是，每个刀齿两侧的刃口曲线及其上每点在滚刀螺旋面上螺旋角都不一样，使得环面蜗轮滚刀的制造特别复杂和困难，至今未解决滚刀的高精度和高效率制造问题，制约着环面蜗杆传动的推广应用。 基于超复杂的各种环面蜗轮滚刀螺旋面的成形理论，研究各种环面蜗轮滚刀各不连续刀齿的超复杂分段曲面不完全设计理论；基于共轭曲面理论，采用最简单最有效的平面或锥面产形面，研究超复杂分段曲面的展成理论和方法；研究适用于各种环面蜗轮滚刀的各个刀齿连续展成理论，使各刀齿的侧刀刃带宽度和侧后角面满足要求并保持一致性；研究环面蜗轮滚刀刀齿的磨削技术和进行误差分析，通过磨削出环面蜗轮滚刀刀齿、测量侧刀刃带宽度和侧后角面角度，验证该理论的可行性和正确性，为提高环面蜗轮滚刀的制造水平及环面蜗杆副的质量提供理论和实用技术支撑。

环面蜗杆传动具有多齿双线接触等特点，相较于传统圆柱蜗杆传动具有更高的传动效率，更大的承载能力。环面蜗杆传动符合国内外齿轮行业追求的轻量化、高效和使用寿命长的发展方向，尤其是平面和双锥面二次包络环面蜗杆传动在我国机械传动领域具有独特的代表性。但该类传动特殊的结构特点，使其设计和加工比较复杂。用于加工对应蜗轮的环面蜗轮滚刀的结构更加复杂，加工难度更大。环面蜗杆的产形原理使得其对应的滚刀的每一个刀齿都具有不同的刃口线形状，难以像普通圆柱滚刀那样使用计算好截面形状的砂轮统一对所有的齿进行铲磨。因此，环面蜗轮滚刀制造是环面蜗杆传动制造的关键，是影响环面蜗杆副传动精度、成本和生产周期的关键问题。由于环面滚刀侧后角面多为手工磨削，滚刀侧刀刃带的一致性和侧刀刃口无法控制，侧后角面的角度大小也无法保证，使得蜗轮质量不高，环面蜗杆传动的精度不能提高和保证，生产水平也一直无法提高，急需解决滚刀后角的数控磨削技术问题。为此，本项目提出“超复杂分段曲面不完全设计和连续展成理论及环面蜗轮滚刀磨削技术研究”的课题。研究了环面蜗轮滚刀刃带面的设计方法；提出了环面蜗轮滚刀侧后角面的不完全设计方法；采用最简单最有效的产形面，研究了侧后角面的数控方法，使各刀齿的侧刀刃带宽度和侧后角面满足要求并保持一致性；研究了环面滚轮滚刀螺旋槽前刀面的设计方法，并进行了修正研究；研究了环面蜗轮滚刀侧后角面连续展成时刀齿的密度设计，避免磨削时的干涉现象；研究了机床定位误差对侧后角面磨削的影响规律等。本环面蜗轮滚刀刀齿的超复杂分段曲面不完全设计理论和连续展成理论和方法适用于各种环面蜗轮滚刀的侧后角面磨削，因为是直接连续展成侧后角面，因此制造效率和精度高，为提高环面蜗轮滚刀的制造水平及环面蜗杆副的质量提供理论和实用技术支撑。