Y54 inserts the precision that helical gear of the tine that make a rod inserts on tine machine to assure
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5 ° . When machining C archives gear, the treatment on tine machine must be inserted in inclined tine. The tooth form treatment of C archives gear is used insert tine, craft of radial shave tine, the final precision after heat treatment cementite quenchs asks to reach 8 level (GB10095, 88) . Precision of the gear after shave ages can raise 1 ～ 1.
5 class, and after heat treatment cementite quenchs, make gear precision drops 2 class of 1 ～ . Integrated consideration, the precision that formulate inserts tine working procedure to should be achieved is 6 ～ between 7 class, specific requirement is: ≤ of Ff of teeth shape error 0.
01mm, ≤ of Fb of teeth directional error 0.
01mm, variation of length of public law line Fw ≤ 0.
025mm, ≤ of pitch deviation Fpt 0.
012mm, pitch accumulates error Fp ≤ 0.
04mm, tine encircles ≤ of radial and jumpy Fr 0.
03mm, ra3 of exterior surface roughness.
2µm. For managing, my factory inserted a Y54 that originates in 70 time initial stage tine machine to undertake maintaining transforming, optimized machining complex to achieve helical gear to insert the output that cuts working procedure and quality requirement. Specific as follows. 1 machine tool is repaired reach worm wheel deputy adjust installation well-known, the pitch that the treatment that insert tine machines than gear hobbing accumulates variation of length of line of error Fp, public law Fw is gotten greatly much, because insert catenary of tine machine drive to go up,this is (cutting tool comes workpiece) have deputy be caused by of two worm wheel, namely tool carrier (cutting tool) worm wheel deputy with workbench worm wheel deputy (deputy) of the worm wheel that divide tine: And gear-hobbing machine has a workbench only (cent ages) worm wheel deputy. Deputy pitch deviation, pitch accumulates worm wheel the error is right influence of error be accumulatived by the pitch error of treatment gear, pitch is most sensitive. Accordingly, when be being maintained besides change necessary fragile, scrape slideway restores precision outside, emphasize deputy to worm wheel with " the error is quits law " undertake repair is adjusted, raised machine tool precision. Disassemble Y54 inserts on tine machine two worm wheel deputy, after burr of clear scour off, worm wheel is measured in PESU640 gear measure on the center, discover although wear extent is bigger, amount to 0.
40mm is controlled () of transverse tooth thickness, but of every tine wear away evener, because worm wheel rotate speed is slower,this is, the reason with lubricant good case: But measure the pitch that give to accumulate an error bigger, it is Fp labour =0 respectively.
09mm, fp knife =0.
065mm, its error curve is shown 2 times like the graph. Wear away because of the tooth form of worm wheel evener, reason need not change, not mandatory also answer, in order to save workload and fund. And worm rotate speed is high, wear extent is big and inhomogenous, need refashion, undertake deserving to grind with worm wheel on Y7520W whorl grinder, obtain a provision till the contact asks. Graph the place such as 2 Peng Dong Lin is written " logical choice and machine tool precision raise cutting tool of the machine that insert tine " (print at " production technology and machine tool " 1998 the 1st period) one document points out, the machine that insert tine transmission error basically depends on tool carrier worm wheel deputy with workbench worm wheel deputy, if can make cutting tool worm wheel deputy accumulation error and workbench worm wheel deputy accumulation error balance disappear, can raise precision of the machine that insert tine effectively. Be based on afore-mentioned train of thought, installing two worm gear deputy when, with the method that tries angrily semifinished product actually, cut base of a tine to measure a pitch error namely, secure the worm wheel that divide tine next, roll adjusts cutting tool worm wheel, via counting second cutting tine base adjusts cutting tool worm wheel, can make deputy pitch accumulates two worm wheel the error is quits spend to the smallest Cheng (at this moment error curve just differs 180 ° ) , make be accumulated by the pitch of treatment gear thereby the error reachs the least value, the precision of the machine tool also rose. If curve of error of deputy synthesis of two worm wheel pursues 2 are shown. Worm wheel is installed deputily, besides use " the error is quits law " outside, still need an attention to make sure radial is jumpy, axial change is moved wait for project requirement. Of 2 machine tools change one's costume or dress of the machine tool change one's costume or dress include 3 fields: Helix slideway, add the aperture inside main shaft of tall, workbench to increase. Helix slideway inserts the motion of scarfing gear, divide outside having all campaign that insert straight tine, still need complementary sum a campaign, namely cutter shaft (cutting tool) add whirligig, such ability make inclined tine inserts tine knife and form of the gear that be inserted to become pair of to bite to concern, insert a helical gear thereby. The add whirligig of cutter shaft relies on helix slideway to come true, helix slideway cent is fixed, slip two parts. Slip helix slideway is made by material of HT300 grey iron, install the cone in cutter shaft upside: Fixed slideway is comprised by 3, the clearance after an intermediate in order to adjusts slideway face to wear away (be equivalent to setting iron) , with HT300 grey mouth cast-iron material is made can, two slideway use stannic bronze on the side make, if termless, usable also wear-resisting is cast-iron make, installation of fixed helix slideway is in tool carrier worm wheel deputy inside aperture surface. Answer to have oil groove on face of slideway of slip, fixed helix, so that lubricate normally, prevent to be pulled, bite wool (bite dead even) and influence precision (cannot work even) . The design of helix slideway makes the lead that gives helix slideway by computation of parameter of the gear that give out, knife that insert tine first be Px=Px0=pmz0=pmtz0sinbtanb type in: Px -- the lead Px0 of helix slideway -- the lead Mt of the knife that insert tine -- M of end panel modulus -- gear modulus Z0 -- inclined tine inserts tine tooth to count B -- helix angle of helical gear reference circle (insert helix angle of tine knife reference circle namely) the lead that gives according to computation, undertake milling and in order to are measured. The treatment craft of helix slideway: Cast, turning, milling slideway face, face of authentic oil groove, deserve to blow slideway cover. The key that helix slideway machines is milling slideway face, must match accurately by lead hang annulus: It is to deserving to blow next secure and when sliding slideway face, edge scrape edge is measured on slideway appearance, if lead error is big, machine the out of tolerance of Fb of error of gear teeth directional that go out, shave of the path after making ages working procedure cannot be corrected, cause gear-box noise finally to increase. When having lead appearance, the lead of helix slideway can undertake on Y3150E gear-hobbing machine simple and easy measure, reach through computation lead. Specific measure reach computational method to consult what Gao Shuojun writes please " inclined tine inserts parameter of slideway of tine machine helix method of simple and easy test " (print at " car gear " 1991 the 1st period) . When the machine tool is used, should prevent helix slideway to bite pull hair. Y54 inserts tine machine not to have automatic lubricant device, notice every order needs to work overtime 32# or 46# mechanical oil twice in helix slideway upper part (before, each) in the class, and lube should pass filter, cannot have dirt sundry scrap. Helix slideway proper motion designs production charge to be controlled in 1000 yuan 3 probably, more managing than be being bought to professional manufacturer 30 thousand multivariate. Because the axis is longer among gear-box,aperture of workbench main shaft is increased, need to load the circle outside Zun Duan Ø65mm aperture of workbench main shaft when treatment inside, in order to reduce treatment height. But main shaft aperture is too small, cannot install workpiece. Tear open next main shaft to reach Kong Che Ø75mm, deepness 130mm. Add tall after Zun Duan puts the intermediate axis that changes his costume or dress to be machined into aperture of workbench main shaft, the height of the machine tool is insufficient still, need to add tall 135mm via computation. Make two add with HT200 casting pig tall piece, tall 135mm, length and go up, scales of next lathe bed union long, width 120mm, classics treatment plane abrasion after two underside, originally closely to combine a face to go up in next lathe bed first, originally upper bed of the machine that insert tine closely again adding tall piece on, of such machine tools insert cut height to increase 135mm. 3 clamping apparatus are inserted when cutting C gear, with the circle outside Ø65mm right end panel locates, the circle outside Ø65mm uses stretch collet (go up embryo) clip is held and locate, go up the embryo is fixed go up in plane of workbench main shaft: When aging to prevent to insert, the axis is askew because of getting power, cause gear precision error, the design makes one tailstock, installation is on workbench of the machine that insert tine, withstand with tailstock tip the axis intermediate is right upright center aperture. The tip should notice when installing tailstock 60 ° cone and aperture of workbench main shaft (or go up fetal center) coaxial is spent be less than 0.
01mm, solid bolt is tightened after school just in time, two Ø10mm awl sells reoccupy fixed position. Inclined tine of the application when the 4 knives that insert tine insert scarfing gear inserts tine knife, and helix angle is equal, way is opposite, gear dextrorotation, insert tine Dao Zunxuan. Choose the knife that insert tine to should notice: The place such as Dong Lin writes the affirmatory Qian Shupeng of knife of Z of number of the tooth that insert tine " logical choice and machine tool precision raise cutting tool of the machine that insert tine " put forward in one article: When the tooth that insert tine several Z knife is more than workpiece tine to count Z man-hour, cutting tool worm wheel deputy error mirrors enlarge on workpiece: Because this wants to choose cutting tool as far as possible tine number is a few less and Z is versed in / Z knife is integer or make cutting tool worm wheel deputy the cutting tool tine that answers null as soon as possible is counted, be helpful for stabilize and raising the precision that insert tine. Be versed in this a little bit cannot be accomplished when choosing the knife that insert tine in Bencijia. Because Z=21 of workpiece tine number is too small, if choose the tooth that insert tine to number is less than or be equal to workpiece tine number, will because of tool carrier body and add the tailstock of outfit to produce collision, and the knife that insert tine is less than gear of workpiece C archives with respect to the contact at all. Because the structure is restricted, the condition that Z of Z knife ≤ is versed in cannot be satisfied, but below the premise that affirmatory cutting tool ages answer to allow in structural dimension when number, take as far as possible a few smaller, decide Z knife =30 finally via computation. Cutting tool needs coating to insert the material that cuts gear to be 20CrMnTi, the tenacity of this material is very good, stick a knife easily. When inserting scarfing gear, the knife that insert tine is even add one whirligig, straighter than inserting tine needs cutting requirement. Insert tine knife with common high-speed steel, machine blade of cutting of many 10 cutting tool to pull hair namely, cutting function drops cause machine tool flutter to produce abnormal knocking, chajula hurts tooth flank surface roughness, need to wear face of the knife before cutting tool again, cutting tool life and productivity are low, product quality is unwarrantable. If convert,TiN coating inserts tine knife, can machine many 100 ability to need to grind cutting tool again continuously, manufacturing efficiency and cutting tool life rise greatly, the value also reduces tooth flank surface roughness subsequently. Coating requires the cost of the knife that insert tine to increase 200 yuan or so only. The normalizing of 5 workpiece material controls workpiece material 20CrMnTi, beforehand heat treatment working procedure is normalizing, normalizing hardness 156 ～ 207HB, range is too wide, and sometimes normalizing hardness and organization all do not cause cutting tool collapse blade and pull hair. For this, we undertook controlling to the normalizing working procedure of workpiece, working procedure standard accuses to narrow inside its hardness to 165 ～ 195HB, and undertook formulary to organization and hardness uniformity, make the processability of material can maintain insert cut a demand. Of 6 cutting fluid choose when inserting inclined tine, of cutting fluid reasonable choose, crucial to tooth flank quality. Use 46# mechanical oil formerly, tooth flank pulls Mao Yan to weigh, surface roughness value is great, control in 10µm commonly. Convert after rape oil, treatment quality has cutting function and workpiece to rise apparently, the life of cutting tool also got ameliorative: But after using 3 months, oily viscosity increases apparently, appeared the phenomenon that scrap sticks on tooth flank and cutting tool, when inserting tine, appear sodden tooth and explode knife. After using rape oil to regard cutting as fluid, an oily dirty is difficult cleared, inconvenience of care and maintenance. Be aimed at this kind of circumstance, reoccupy is very rich the company makes " cutting beautiful 570AN " have a test as the cutting fluid that inserts inclined tine. "Cutting beautiful 570AN " the oil that is transparent, light color, without peculiar smell, it joins chloride, sulfide and lubricant to wait to additive is allocated and be become by certain recipe by mineral oil. The effect when inserting scarfing to age is apparent, tooth flank surface roughness can be stabilized commonly in Ra3.
2µm is the following, did not discover tooth flank is pulled wool and the appearance that has scrap is stuck on workpiece, cutting tool, oily mist is very few also, cutting tool life rises, grind treatment from blade 100 rise reach 250, and the stability of dimension also rises somewhat, machine tool Yi Qingjie maintains, welcome by handlers. "Cutting beautiful 570AN " the price is one times more expensive than rape oil, but its are mixed to workpiece quality of cutting tool life improve the result remarkable, performance/price ratio is accordingly good, be worth promotion application. Besides each afore-mentioned content, still should use right cutting dosage, wait like stroke of move back and forth, circumferential feed, radial feed. Practice makes clear, classics of useless old machine tool maintains Y54, change one's costume or dress, axial helical gear is machined among the small lot in all-round is over to suit after adjusting, precision also can satisfy working procedure requirement, achieved expect an end, its maintenance, changeover cost does not exceed 2.
50 thousand yuan. CNC Milling