Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional ph...Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality.The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement.Therefore,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings.The origin of curvic tooth surface error is deeply investigated.Using 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired efficiently.Based on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts.Experimental results show that the assembly precision can be predicted accurately and improved dramatically.By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.展开更多
A dynamic model of a helical gear rotor system is proposed.Firstly,a generally distributed dynamic model of a helical gear pair with tooth profile errors is developed.The gear mesh is represented by a pair of cylinder...A dynamic model of a helical gear rotor system is proposed.Firstly,a generally distributed dynamic model of a helical gear pair with tooth profile errors is developed.The gear mesh is represented by a pair of cylinders connected by a series of springs and the stiffness of each spring is equal to the effective mesh stiffness.Combining the gear dynamic model with the rotor-bearing system model,the gear-rotor-bearing dynamic model is developed.Then three cases are presented to analyze the dynamic responses of gear systems.The results reveal that the gear dynamic model is effective and advanced for general gear systems,narrow-faced gear,wide-faced gear and gear with tooth profile errors.Finally,the responses of an example helical gear system are also studied to demonstrate the influence of the lead crown reliefs and misalignments.The results show that both of the lead crown relief and misalignment soften the gear mesh stiffness and the responses of the gear system increase with the increasing lead crown reliefs and misalignments.展开更多
In this work,synchronous cutting of concave and convex surfaces was achieved using the duplex helical method for the hypoid gear,and the problem of tooth surface error correction was studied.First,the mathematical mod...In this work,synchronous cutting of concave and convex surfaces was achieved using the duplex helical method for the hypoid gear,and the problem of tooth surface error correction was studied.First,the mathematical model of the hypoid gears machined by the duplex helical method was established.Second,the coordinates of discrete points on the tooth surface were obtained by measurement center,and the normal errors of the discrete points were calculated.Third,a tooth surface error correction model is established,and the tooth surface error was corrected using the Levenberg-Marquard algorithm with trust region strategy and least square method.Finally,grinding experiments were carried out on the machining parameters obtained by Levenberg-Marquard algorithm with trust region strategy,which had a better effect on tooth surface error correction than the least square method.After the tooth surface error is corrected,the maximum absolute error is reduced from 30.9μm before correction to 6.8μm,the root mean square of the concave error is reduced from 15.1 to 2.1μm,the root mean square of the convex error is reduced from 10.8 to 1.8μm,and the sum of squared errors of the concave and convex surfaces was reduced from 15471 to 358μm^(2).It is verified that the Levenberg-Marquard algorithm with trust region strategy has a good accuracy for the tooth surface error correction of hypoid gear machined by duplex helical method.展开更多
In order to analyze the influence of setting error of tool on both tooth profile and contact characteristic of orthogonal face gear drive,the coordinate systems with and without setting error are established.Moreover,...In order to analyze the influence of setting error of tool on both tooth profile and contact characteristic of orthogonal face gear drive,the coordinate systems with and without setting error are established.Moreover,the equations of tooth profile and contact points of face gear drive are derived by envelope principle.According to the equations,the change of tooth profile and the contact points position on face gear are analyzed.The tooth surface and contact points are obtained by numerical simulation.Results show that the tooth profile and contact characteristic of face gear drive are not sensitive to the setting error of tool.展开更多
In order to generate the digital gear tooth surfaces(DGTS)with high efficiency and high precision,a method for identification and compensation of machining errors is demonstrated in this paper.Machining errors are ana...In order to generate the digital gear tooth surfaces(DGTS)with high efficiency and high precision,a method for identification and compensation of machining errors is demonstrated in this paper.Machining errors are analyzed directly from the real tooth surfaces.The topography data of the part are off-line measured in the post-process.A comparison is made between two models:CAD model of DGTS and virtual model of the physical measured surface.And a matching rule is given to determine these two surfaces in an appropriate fashion.The developed error estimation model creates a point-to-point map of the real surface to the theoretical surface in the normal direction.A“pre-calibration error compensation”strategy is presented.Through processing the results of the first trail cutting,the total compensation error is predicted and an imaginary digital tooth surface is reconstructed. The machining errors in the final manufactured surfaces are minimized by generating this imaginary surface.An example of ma- chining 2-D DGTS verifies the developed method.The research is of important theoretical and practical value to manufacture the DGTS and other digital conjugate surfaces.展开更多
The basic principle of equal base circle bevel gear (EBCBG) is illustrated simply Thetooth surface equation of EBCBG manufactured by end milling cutter with involute profile is de-rived. The tooth form error is analy...The basic principle of equal base circle bevel gear (EBCBG) is illustrated simply Thetooth surface equation of EBCBG manufactured by end milling cutter with involute profile is de-rived. The tooth form error is analyzed on the basis of spherical involute展开更多
This paper proposes a new approach to design pinion machine tool-settings for spiral bevel gears by controlling contact path and transmission errors. It is based on the satisfaction of contact condition of three given...This paper proposes a new approach to design pinion machine tool-settings for spiral bevel gears by controlling contact path and transmission errors. It is based on the satisfaction of contact condition of three given control points on the tooth surface. The three meshing points are controlled to be on a predesigned straight contact path that meets the pre-designed parabolic function of transmission errors. Designed separately, the magnitude of transmission errors and the orientation of the contact path are subjected to precise control. In addition, in order to meet the manufacturing requirements, we suggest to modify the values of blank offset, one of the pinion machine tool-settings, and redesign pinion ma- chine tool-settings to ensure that the magnitude and the geometry of transmission errors should not be influenced apart from minor effects on the predesigned straight contact path. The proposed approach together with its ideas has been proven by a numerical example and the manufacturing practice of a pair of spiral bevel gears.展开更多
The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG).However,a corresponding efficient method for e...The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG).However,a corresponding efficient method for eliminating or reducing these errors on the tooth profile of the ADEHWG is seldom reported.The gear engagement equation and tooth profile equation for considering six different errors that could arise from the machining and gear misalignment are derived from the theories of differential geometry and gear meshing.Also,the tooth contact analysis(TCA) is used to systematically investigate the influence of the machining and misalignment errors on the contact curves and the tooth profile by means of numerical analysis and three-dimensional solid modeling.The research results show that vertical angular misalignment of the worm wheel(Δβ) has the strongest influences while the tooth angle error(Δα) has the weakest influences on the contact curves and the tooth profile.A novel efficient approach is proposed and used to minimize the effect of the errors in manufacturing by changing the radius of the grinding wheel and the approaching point of contact.The results from the TCA and the experiment demonstrate that this tooth profile design modification method can indeed reduce the machining and misalignment errors.This modification design method is helpful in understanding the manufacturing technology of the ADEHWG.展开更多
基金co-supported by the National Basic Research Project(Nos.J2022-VII-0001-0043 and 2017-VII-0010-0104)the Fundamental Research Funds for the Central Universities,and the National Natural Science Foundation of China(No.72231008)。
文摘Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality.The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement.Therefore,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings.The origin of curvic tooth surface error is deeply investigated.Using 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired efficiently.Based on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts.Experimental results show that the assembly precision can be predicted accurately and improved dramatically.By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.
基金Projects(51605361,51505357) supported by the National Natural Science Foundation of ChinaProjects(XJS16041,JB160411) supported by the Fundamental Research Funds for the Central Universities,China
文摘A dynamic model of a helical gear rotor system is proposed.Firstly,a generally distributed dynamic model of a helical gear pair with tooth profile errors is developed.The gear mesh is represented by a pair of cylinders connected by a series of springs and the stiffness of each spring is equal to the effective mesh stiffness.Combining the gear dynamic model with the rotor-bearing system model,the gear-rotor-bearing dynamic model is developed.Then three cases are presented to analyze the dynamic responses of gear systems.The results reveal that the gear dynamic model is effective and advanced for general gear systems,narrow-faced gear,wide-faced gear and gear with tooth profile errors.Finally,the responses of an example helical gear system are also studied to demonstrate the influence of the lead crown reliefs and misalignments.The results show that both of the lead crown relief and misalignment soften the gear mesh stiffness and the responses of the gear system increase with the increasing lead crown reliefs and misalignments.
基金Projects(52075552,51575533,51805555,11662004)supported by the National Natural Science Foundation of China。
文摘In this work,synchronous cutting of concave and convex surfaces was achieved using the duplex helical method for the hypoid gear,and the problem of tooth surface error correction was studied.First,the mathematical model of the hypoid gears machined by the duplex helical method was established.Second,the coordinates of discrete points on the tooth surface were obtained by measurement center,and the normal errors of the discrete points were calculated.Third,a tooth surface error correction model is established,and the tooth surface error was corrected using the Levenberg-Marquard algorithm with trust region strategy and least square method.Finally,grinding experiments were carried out on the machining parameters obtained by Levenberg-Marquard algorithm with trust region strategy,which had a better effect on tooth surface error correction than the least square method.After the tooth surface error is corrected,the maximum absolute error is reduced from 30.9μm before correction to 6.8μm,the root mean square of the concave error is reduced from 15.1 to 2.1μm,the root mean square of the convex error is reduced from 10.8 to 1.8μm,and the sum of squared errors of the concave and convex surfaces was reduced from 15471 to 358μm^(2).It is verified that the Levenberg-Marquard algorithm with trust region strategy has a good accuracy for the tooth surface error correction of hypoid gear machined by duplex helical method.
基金Supported by the National Natural Science Foundation of China(51105194)the Scientific Research Funding of Nanjing University of Aeronautics and Astronautics(NP2011014)
文摘In order to analyze the influence of setting error of tool on both tooth profile and contact characteristic of orthogonal face gear drive,the coordinate systems with and without setting error are established.Moreover,the equations of tooth profile and contact points of face gear drive are derived by envelope principle.According to the equations,the change of tooth profile and the contact points position on face gear are analyzed.The tooth surface and contact points are obtained by numerical simulation.Results show that the tooth profile and contact characteristic of face gear drive are not sensitive to the setting error of tool.
文摘In order to generate the digital gear tooth surfaces(DGTS)with high efficiency and high precision,a method for identification and compensation of machining errors is demonstrated in this paper.Machining errors are analyzed directly from the real tooth surfaces.The topography data of the part are off-line measured in the post-process.A comparison is made between two models:CAD model of DGTS and virtual model of the physical measured surface.And a matching rule is given to determine these two surfaces in an appropriate fashion.The developed error estimation model creates a point-to-point map of the real surface to the theoretical surface in the normal direction.A“pre-calibration error compensation”strategy is presented.Through processing the results of the first trail cutting,the total compensation error is predicted and an imaginary digital tooth surface is reconstructed. The machining errors in the final manufactured surfaces are minimized by generating this imaginary surface.An example of ma- chining 2-D DGTS verifies the developed method.The research is of important theoretical and practical value to manufacture the DGTS and other digital conjugate surfaces.
文摘The basic principle of equal base circle bevel gear (EBCBG) is illustrated simply Thetooth surface equation of EBCBG manufactured by end milling cutter with involute profile is de-rived. The tooth form error is analyzed on the basis of spherical involute
基金National Natural Science Foundation of China (50475148)Aeronautical Science Foundation of China (04C53015)Areonautical Sci-tech Innovation Foundation of China (07B53004)
文摘This paper proposes a new approach to design pinion machine tool-settings for spiral bevel gears by controlling contact path and transmission errors. It is based on the satisfaction of contact condition of three given control points on the tooth surface. The three meshing points are controlled to be on a predesigned straight contact path that meets the pre-designed parabolic function of transmission errors. Designed separately, the magnitude of transmission errors and the orientation of the contact path are subjected to precise control. In addition, in order to meet the manufacturing requirements, we suggest to modify the values of blank offset, one of the pinion machine tool-settings, and redesign pinion ma- chine tool-settings to ensure that the magnitude and the geometry of transmission errors should not be influenced apart from minor effects on the predesigned straight contact path. The proposed approach together with its ideas has been proven by a numerical example and the manufacturing practice of a pair of spiral bevel gears.
基金supported by National Natural Science Foundation of China(Grant Nos. 50775190No.51275425)+2 种基金Spring Sunshine Plan of Ministry of Education of China(Grant No. 10202258)Talent Introduction of Xihua UniversityChina(Grant No. Z1220217)
文摘The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG).However,a corresponding efficient method for eliminating or reducing these errors on the tooth profile of the ADEHWG is seldom reported.The gear engagement equation and tooth profile equation for considering six different errors that could arise from the machining and gear misalignment are derived from the theories of differential geometry and gear meshing.Also,the tooth contact analysis(TCA) is used to systematically investigate the influence of the machining and misalignment errors on the contact curves and the tooth profile by means of numerical analysis and three-dimensional solid modeling.The research results show that vertical angular misalignment of the worm wheel(Δβ) has the strongest influences while the tooth angle error(Δα) has the weakest influences on the contact curves and the tooth profile.A novel efficient approach is proposed and used to minimize the effect of the errors in manufacturing by changing the radius of the grinding wheel and the approaching point of contact.The results from the TCA and the experiment demonstrate that this tooth profile design modification method can indeed reduce the machining and misalignment errors.This modification design method is helpful in understanding the manufacturing technology of the ADEHWG.
