A new electronic gearbox for gear hobbing machines

Tian, Xiaoqing; Han, Jiang; Xia, Lian

doi:10.1177/0954405414564405

Cited by 7 publications

(3 citation statements)

References 15 publications

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“…Nowadays, the EGB control technique has been applied to cylindrical gear processing machine tool, gear measuring equipment such as gear hobbing machine, gear shaping machine, gear honing machine, gear grinding machine, gear measuring center, etc. [19,20] and other fields need to be synchronized control. For gear machining, the gear tooth profile can be enveloped shaping through the synchronous movement of cutter spindle, workpiece spindle, and feed shafts.…”

Section: Linkage Model Of Non-circular Gear Hobbingmentioning

confidence: 99%

Non-circular gear continuous generating machining interpolation method and experimental research

Han

Zhu

et al. 2017

J Braz. Soc. Mech. Sci. Eng.

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Current non-circular gear manufacturing process all use discrete machining method, which generates a large number of small line segments, brings in approximate error, and leads to high-order discontinuity of the whole tool path curve. The tooth surface quality will be decreased significantly due to the vibration of machining tool caused by the discontinuity of machine tool motion trajectory especially in high-speed machining. In addition, the processing speed and efficiency will be limited due to the unsmooth kinematics profile. This paper proposes a noncircular gear completely continuous generating machining interpolation method. The non-circular gear machining electronic gearbox is developed to compute the real-time interpolation point data to guarantee the strict generating motion relationship between the workpiece spindle, feed shaft, and cutter spindle during the gear manufacturing process according to the derived linkage model for noncircular gear hobbing and generate continuous smooth machining trajectory. The proposed interpolation method is implemented on the self-developed CNC system based on the embedded CNC system hardware structure platform and verified experimentally on a gear hobbing machine. A pair of two-order oval non-circular gear is machined, and the roll and application experiments on a kind of gear pumps are done to illustrate the machining performance and provide a high efficiency and precision machining method for non-circular gear.

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Section: Linkage Model Of Non-circular Gear Hobbingmentioning

confidence: 99%

Non-circular gear continuous generating machining interpolation method and experimental research

Han

Zhu

et al. 2017

J Braz. Soc. Mech. Sci. Eng.

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“…It can be used for tooth profile error modification of worm hobs or grinding cutters on freeform multi-axis CNC machine tools. Tian et al 14 proposed a new software-defined electronic gearbox applied to the hobbing computer numerical control, and experiments with different gear hobbing methods were carried out to verify its good performance. Liu et al 15 introduced a method for the relief grinding of a flat double-envelope worm gear hob on multi-axis CNC worm gear grinders, thereby realising that the hob can be automatically relief ground under different cutting-edge shapes and helical angles.…”

Section: Introductionmentioning

confidence: 99%

Modelling and experiment of gear hob tooth profile error for relief grinding

Yang

Chen

Wang

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Gear hob is an important tool that is most used in gear processing. Hob accuracy directly exerts an overwhelming influence on the quality of the processed gear. Generally, the hob tooth profile accuracy is mainly determined by relief grinding process. Studies on tooth profile errors of gear hobs caused by severe friction and cutting with the high-speed rotation of the wheel during the form grinding machining of hobs are limited. Thus, a theoretical model of the tooth profile error prediction under different machining parameters was established based on the analysis of coupling influence of high temperature and high strain rate on gear hobs in the relief grinding process. The model was completed on the basis of the dynamic explicit integral finite element method of thermo-mechanical coupling. Through the prediction model, the influence of the grinding depth ap, feed speed Vw and grinding speed Vs on the tooth profile error can be analysed. In addition, an algorithm for accurately calculate the grinding wheel axial profile by combining instantaneous envelope theory and hob normal tooth profile was proposed. The hob relief grinding experiments were carried out using the proposed grinding wheel profile algorithm. The relative error of the prediction obtained by comparing the calculation results of the prediction model with the experimental results is within 10%. Results prove the validity of the prediction model. This finding is greatly important for optimising the accuracy of hob relief grinding.

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“…Based on the principle of milling and the theory of gear meshing, Wang et al 5 put forward a high-efficiency and high precision machining method of spur face gear. Han et al 6 and Tian et al 7 proposed an embedded reconfigurable EGB platform which contains parametric programming and process database module and verified the correctness and effectiveness of the platform on a six-axis gear hobbing machine. Some classical error modeling methods for machine tool processing, such as Denavit-Hartenberg (D-H), rigid body kinematics, homogeneous transformation matrix (HTM) and screw theory, have been developed in previous research works.…”

Section: Introductionmentioning

confidence: 99%

Modeling and adaptive compensation of tooth surface contour error for internal gearing power honing

Han

Zhu

Xia

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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The machining of high precision gears requires a strict and accurate co-movement relationship controlled by the electronic gearbox between the moving axes of the gear machine tools. This article proposes a tooth surface contour error modeling method and an adaptive electronic gearbox cross-coupling controller for internal gearing power honing. First, the electronic gearbox model is structured according to the generative machining principle of internal gearing power honing and the tooth surface contour error is established by means of homogeneous coordinate transformation and meshing principle. Then, the adaptive electronic gearbox cross-coupling controller is designed, which comprises the electronic gearbox cross-coupling controller and the fuzzy proportional–integral–derivative controllers whose universes of membership functions in fuzzy rules are optimized by particle swarm optimization to improve the adaptability and robustness to disturbance fluctuation and model uncertainty of the system. Finally, experiments are carried out on a self-developed gear numerical control system. The results have demonstrated that the estimated tooth surface contour error using the proposed method is very close to the actual one, and the proposed adaptive electronic gearbox cross-coupling controller can effectively reduce the tracking error and the tooth surface contour error when compared to the electronic gearbox cross-coupling controller and non–electronic gearbox cross-coupling controller (electronic gearbox controller without cross-coupling and adaptive compensation).

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A new electronic gearbox for gear hobbing machines

Cited by 7 publications

References 15 publications

Non-circular gear continuous generating machining interpolation method and experimental research

Non-circular gear continuous generating machining interpolation method and experimental research

Modelling and experiment of gear hob tooth profile error for relief grinding

Modeling and adaptive compensation of tooth surface contour error for internal gearing power honing

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