Hobbing is one of the crucial gear manufacturing processes with high precision and high efficiency.In order to improve the accuracy of hobbing and hob relief grinding,more precise grinding wheels are demanded for reli...Hobbing is one of the crucial gear manufacturing processes with high precision and high efficiency.In order to improve the accuracy of hobbing and hob relief grinding,more precise grinding wheels are demanded for relief grinding in the production of gear hobs.In this paper,a new and accurate mathematical method for calculating the axial profile of grinding wheel based on the corresponding gear hob to be ground is proposed.Considering that most researches have been conducted to focus on the optimization of hob geometric feature and only can be applied to a specific type of hand of helix and rake angle of gear hobs.The method in this paper can be served as a general algorithm for generating axial profile of grinding wheels on the basis of the spatial envelope theory,the principle of coordinate system transformation,and studies on normal profile of single-tooth.The accuracy of grinding hobs is based on applying the approach in practical manufacturing.Taking two typical different kinds of pre-grinding gear hobs as examples for calculation and experiment,the results of tooth profile errors strengthen the position that the validity and feasibility of this method,it can be employed for gear hob design and grinding processing.展开更多
Accurate prediction of manufacturing carbon emissions is of great significance for subsequent low-carbon optimization.To improve the accuracy of carbon emission prediction with insufficient hobbing data,combining the ...Accurate prediction of manufacturing carbon emissions is of great significance for subsequent low-carbon optimization.To improve the accuracy of carbon emission prediction with insufficient hobbing data,combining the advantages of improved algorithm and supplementary data,a method of carbon emission prediction of hobbing based on cross-process data fusion was proposed.Firstly,we analyzed the similarity of machining process and manufacturing characteristics and selected milling data as the fusion material for hobbing data.Then,the adversarial learning was used to reduce the difference between data from the two processes,so as to realize the data fusion at the characteristic level.After that,based on Meta-Transfer Learning method,the carbon emission prediction model of hobbing was established.The effectiveness and superiority of the proposed method were verified by case analysis and comparison.The prediction accuracy of the proposed method is better than other methods across different data sizes.展开更多
Proper meshing of Hy-Vo silent chain and sprocket is important for realizing the transmission of the silent chain with more efficiency and less noise. Based on the study of the meshing theory of the Hy-Vo silent chain...Proper meshing of Hy-Vo silent chain and sprocket is important for realizing the transmission of the silent chain with more efficiency and less noise. Based on the study of the meshing theory of the Hy-Vo silent chain with the sprocket and the roll cutting machining principle of the sprocket with the hob, the proper conditions of the meshing for the Hy-Vo silent chain and the sprocket are put forward with the variable pitch characteristic of the Hy-Vo silent chain taken into consideration, and the proper meshing design method on the condition that the value of the link tooth pressure angle is unequal to the value of the sprocket tooth pressure angle is studied. Experiments show that this new design method is feasible. In addition, the design of the pitch, the sprocket tooth pressure angle and the fillet radius of the sprocket addendum circle are studied. It is crucial for guiding the design of the hob which cuts the Hy-Vo silent chain sprocket.展开更多
In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear,a precision generating hobbing method for face gear with the assembly spherical hob is proposed.Firstly,the evoluti...In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear,a precision generating hobbing method for face gear with the assembly spherical hob is proposed.Firstly,the evolution of the cylindrical gear to spherical hob basic worm is analyzed,then the spherical hob basic worm is designed,thus the basic worm and spiral angle equation of spherical hob are obtained.Secondly,based on the design method of the existing hob,the development method of the assembly spherical hob is analyzed,the cutter tooth and the cutter substrate of the assembly hob are designed,and the whole assembly is finished.Thirdly,based on the need of face gear hobbing,a numerical control machine for gear hobbing is developed,and the equation of the face gear is obtained.Fourth,for reducing the face gear processing errors induced by equivalent installation errors,the error analysis model is established and the impacts of each error on the gear tooth surface are analyzed.Finally,the assembly spherical hob is manufactured and the gear hobbing test is completed.According to the measurement results,the processing parameters of face gear hobbing are modified,and the deviation of tooth surface is significantly reduced.展开更多
The regrinding error is the main factor affecting the eligible length of hob tooth,how to decrease the regrinding error is a hot issue in the research area of hob grinding.At present,researches focus on changing the t...The regrinding error is the main factor affecting the eligible length of hob tooth,how to decrease the regrinding error is a hot issue in the research area of hob grinding.At present,researches focus on changing the trajectory of relief moving,because of no unified relief grinding path planning method,the research result is restricted in the practical application.For solving the problem,the calculation model of the hob relief angle is established with the Archimedes relieving motion to analyze the interaction between the increasing relief angle of the hob and the accelerating tooth profile errors.Based on it,the improved relief grinding method of gear hob is proposed with equal relief angle（ERA）.Furthermore,the relief grinding method with ERA is developed with the following two steps.Firstly,the convergence numerical solution algorithm of the tooth top curve is designed to form the wheel motion path which is compared with that of traditional grinding.The second step is to establish the solution model of ERA grinding wheel.In order to verify the effect of the method,hob grinding simulation system of 3D solid was built under the AutoCAD environment.The regrinding errors is analyzed by intercepting the hob axial profiles of the various regrinding angles with Boolean operations and further converting it to basic rack tooth,then the simulation example of zero rake straight flute hob is used to compare the regrinding errors between ERA grinding and traditional grinding.Finally,the experiments were implemented on the five-axis CNC relief grinder with the relief motion of ERA grinding driven by cam.The results of experiments show that the method can effectively reduce the regrinding errors of hob and grind expediently gear hob of AA rank and over.This research provide an effective model of relief moving path plan reducing regrinding error,and have practicable value in CNC relief grinder.展开更多
Based on the study of the meshing theory of a new silent chain and sprockets, and the rolling cutting theory of sprocket and hob, the harmonious relations of dominating dimensions among the new silent chain, sprocket ...Based on the study of the meshing theory of a new silent chain and sprockets, and the rolling cutting theory of sprocket and hob, the harmonious relations of dominating dimensions among the new silent chain, sprocket and hob is build, the meshing conditions are expatiated, and the resolved expression, which can instruct design and calculation, is educed. The tests show that the meshing design method is feasible.展开更多
To improve the cutting performance of an hourglass worm gear hob and the accuracy of the resulting worm gear,the rake angles of the teeth on the pitch circle should be reduced.A method of forming the spiral flutes by ...To improve the cutting performance of an hourglass worm gear hob and the accuracy of the resulting worm gear,the rake angles of the teeth on the pitch circle should be reduced.A method of forming the spiral flutes by using a variable transmission ratio was developed.This method ensures that the rake angles on the indexing torus of each tooth are approximately 0°.Based on the gear meshing theory and the hourglass worm forming method,the discretization mathematical model of the rake face of a planar double enveloping worm gear hob was established by using cylindrical generating surface,and the feed parameters for machining the rake face for a variable transmission ratio were obtained.The spiral flute was simulated and the hob was machined on a four axis CNC milling machine.A contourgraph was used to measure the rake angle.The measurement results showed that the proposed method can reduce the absolute value of the rake angle on both sides of the cutting teeth,which can be used for machining the spiral flute rake face of an hourglass worm gear hob.展开更多
A variable inertial damper, whose viscous damping coefficient can be adjusted by changing the gap between inertia wheel and motor spindle, is designed in servomechanism of zero-drive hobbing machine and is directly at...A variable inertial damper, whose viscous damping coefficient can be adjusted by changing the gap between inertia wheel and motor spindle, is designed in servomechanism of zero-drive hobbing machine and is directly attached on the motor spindle. The mathematical model of servo system with inertial damper is built. By using theoretical analysis and system simulation, it is demonstrated that the variable inertial damper with optimal damping coefficient and moment of inertia should lead to no resonance point in wider frequency range of exciting force. Therefore, its application in zero-drive hobbing machine makes this system not only achieve higher system stiffness to overcome load torque fluctuation, but also gain better stability.展开更多
The wear and destruction appearances of hobs are researched. The reasons ofthe wear and destruction of hob are analyzed. And the influence of the change of the hobbing forceand the hobbing temperature on the wear and ...The wear and destruction appearances of hobs are researched. The reasons ofthe wear and destruction of hob are analyzed. And the influence of the change of the hobbing forceand the hobbing temperature on the wear and destruction of hob in gear hobbing is also analyzed. Ingear hobbing, the main wear mechanisms are adhesion and ploughing when cutting the 20CrMnTi gearusing W18Cr4V high-speed steel hob.展开更多
The current research on noncircular hobbing mainly focuses on the linkage model and motion realization.However,the intermittent cutting characteristics of hobbing would increase uncertainties in the manufacturing proc...The current research on noncircular hobbing mainly focuses on the linkage model and motion realization.However,the intermittent cutting characteristics of hobbing would increase uncertainties in the manufacturing process.In this paper,a hobbing machining model with tool-shifting characteristics was proposed to solve the problems of cutting force fluctuation and inconsistency of tooth profile envelope accuracy at different positions of the pitch curve in noncircular gear hobbing.Based on the unit cutting force coefficient method,the undeformed chip volume generated by interrupted cutting was used to characterize the fluctuation trend of the hobbing force.The fluctuation characteristics of the cutting force generated by different hobbing models were compared and analyzed.Using the equivalent gear tooth and hob slotting numbers,an analysis model of the tooth profile envelope error of the noncircular gear was constructed.Subsequently,the tooth profile envelope errors at different positions of the pitch curve were compared and analyzed based on the constructed model.The transmission structure of the electronic gearbox was constructed based on the proposed hobbing model,and the hobbing experiment was conducted based on the selfdeveloped noncircular gear CNC hobbing system.This paper proposes a hobbing method that can effectively suppress the fluctuation of the peak and whole circumference cutting force and reduce the maximum envelope error of the whole circumference gear teeth.展开更多
This paper takes the escapement plate of a mechanical pendulum clock as an example,analyses the design of combination form cutter hob for special profile gears, selection of parameters and calculation for tooth profil...This paper takes the escapement plate of a mechanical pendulum clock as an example,analyses the design of combination form cutter hob for special profile gears, selection of parameters and calculation for tooth profile coordinates and discusses the grinding of cutter hob tooth profile on optical contour grinder.展开更多
The top relief surfaces of an hourglass worm gear hob are ground manually in the traditional manufacturing process,which cannot ensure the width of the land surfaces of the hob.Moreover,each geometric feature of the h...The top relief surfaces of an hourglass worm gear hob are ground manually in the traditional manufacturing process,which cannot ensure the width of the land surfaces of the hob.Moreover,each geometric feature of the hob has been produced through different manufacturing techniques and machine tools,which results in low efficiency.To solve this problem,we propose a semi-automatic computer aided design(CAD)method for hobs.The point clouds of each feature surface of a hob are calculated by combing mathematical equations of the top relief surfaces built by the proposed method with other existing equations of hob surfaces.According to the point clouds,the method can achieve the automatic modeling for the hob in three-dimensional(3D)software by classifying and extracting the parameter information of the feature-hierarchical knowledge of the hob.Based on the generated 3D model,the entire surfaces of the hob can be manufactured on a four-axis computer numerical control(CNC)milling machine through only twice clamping.Verification of the width of the land surface of the hob manufactured by semi-automatic CAD method on a measuring projector proved the precision of the designed width can be ensured.The edge of the contact area on the worm wheel in a meshing experiment is clear and distinct,which means the worm gear drive is meshed well and the hob manufactured by the proposed method has improved machinability.The method simplifies the processing technique,and improves the design efficiency and production accuracy.展开更多
基金National Key Research and Development Project of China(2018YFB2001500)。
文摘Hobbing is one of the crucial gear manufacturing processes with high precision and high efficiency.In order to improve the accuracy of hobbing and hob relief grinding,more precise grinding wheels are demanded for relief grinding in the production of gear hobs.In this paper,a new and accurate mathematical method for calculating the axial profile of grinding wheel based on the corresponding gear hob to be ground is proposed.Considering that most researches have been conducted to focus on the optimization of hob geometric feature and only can be applied to a specific type of hand of helix and rake angle of gear hobs.The method in this paper can be served as a general algorithm for generating axial profile of grinding wheels on the basis of the spatial envelope theory,the principle of coordinate system transformation,and studies on normal profile of single-tooth.The accuracy of grinding hobs is based on applying the approach in practical manufacturing.Taking two typical different kinds of pre-grinding gear hobs as examples for calculation and experiment,the results of tooth profile errors strengthen the position that the validity and feasibility of this method,it can be employed for gear hob design and grinding processing.
基金Supported by National Natural Science Foundation of China(Grant No.52005062)Chongqing Municipal Natural Science Foundation of China(Grant No.CSTB2023NSCQ-MSX0390)。
文摘Accurate prediction of manufacturing carbon emissions is of great significance for subsequent low-carbon optimization.To improve the accuracy of carbon emission prediction with insufficient hobbing data,combining the advantages of improved algorithm and supplementary data,a method of carbon emission prediction of hobbing based on cross-process data fusion was proposed.Firstly,we analyzed the similarity of machining process and manufacturing characteristics and selected milling data as the fusion material for hobbing data.Then,the adversarial learning was used to reduce the difference between data from the two processes,so as to realize the data fusion at the characteristic level.After that,based on Meta-Transfer Learning method,the carbon emission prediction model of hobbing was established.The effectiveness and superiority of the proposed method were verified by case analysis and comparison.The prediction accuracy of the proposed method is better than other methods across different data sizes.
基金This project is supported by National Natural Science Foundation of China(No.50575089).
文摘Proper meshing of Hy-Vo silent chain and sprocket is important for realizing the transmission of the silent chain with more efficiency and less noise. Based on the study of the meshing theory of the Hy-Vo silent chain with the sprocket and the roll cutting machining principle of the sprocket with the hob, the proper conditions of the meshing for the Hy-Vo silent chain and the sprocket are put forward with the variable pitch characteristic of the Hy-Vo silent chain taken into consideration, and the proper meshing design method on the condition that the value of the link tooth pressure angle is unequal to the value of the sprocket tooth pressure angle is studied. Experiments show that this new design method is feasible. In addition, the design of the pitch, the sprocket tooth pressure angle and the fillet radius of the sprocket addendum circle are studied. It is crucial for guiding the design of the hob which cuts the Hy-Vo silent chain sprocket.
基金Project(9140xx8020212xx)supported by the Advanced Research Foundation,ChinaProject(GZ2018KF003)supported by the State Key Laboratory of Smart Manufacturing for Special Vehicles and Transmission System,China
文摘In order to improve the processing precision and shorten the hob manufacturing cycle of the face gear,a precision generating hobbing method for face gear with the assembly spherical hob is proposed.Firstly,the evolution of the cylindrical gear to spherical hob basic worm is analyzed,then the spherical hob basic worm is designed,thus the basic worm and spiral angle equation of spherical hob are obtained.Secondly,based on the design method of the existing hob,the development method of the assembly spherical hob is analyzed,the cutter tooth and the cutter substrate of the assembly hob are designed,and the whole assembly is finished.Thirdly,based on the need of face gear hobbing,a numerical control machine for gear hobbing is developed,and the equation of the face gear is obtained.Fourth,for reducing the face gear processing errors induced by equivalent installation errors,the error analysis model is established and the impacts of each error on the gear tooth surface are analyzed.Finally,the assembly spherical hob is manufactured and the gear hobbing test is completed.According to the measurement results,the processing parameters of face gear hobbing are modified,and the deviation of tooth surface is significantly reduced.
基金supported by the Fundamental Research Funds for the Central Universities (Grant No. CDJZR10110025)
文摘The regrinding error is the main factor affecting the eligible length of hob tooth,how to decrease the regrinding error is a hot issue in the research area of hob grinding.At present,researches focus on changing the trajectory of relief moving,because of no unified relief grinding path planning method,the research result is restricted in the practical application.For solving the problem,the calculation model of the hob relief angle is established with the Archimedes relieving motion to analyze the interaction between the increasing relief angle of the hob and the accelerating tooth profile errors.Based on it,the improved relief grinding method of gear hob is proposed with equal relief angle（ERA）.Furthermore,the relief grinding method with ERA is developed with the following two steps.Firstly,the convergence numerical solution algorithm of the tooth top curve is designed to form the wheel motion path which is compared with that of traditional grinding.The second step is to establish the solution model of ERA grinding wheel.In order to verify the effect of the method,hob grinding simulation system of 3D solid was built under the AutoCAD environment.The regrinding errors is analyzed by intercepting the hob axial profiles of the various regrinding angles with Boolean operations and further converting it to basic rack tooth,then the simulation example of zero rake straight flute hob is used to compare the regrinding errors between ERA grinding and traditional grinding.Finally,the experiments were implemented on the five-axis CNC relief grinder with the relief motion of ERA grinding driven by cam.The results of experiments show that the method can effectively reduce the regrinding errors of hob and grind expediently gear hob of AA rank and over.This research provide an effective model of relief moving path plan reducing regrinding error,and have practicable value in CNC relief grinder.
基金This project is supported by National Natural Science Foundation of China (No.50275062)National Machine Industry Technique Development Foundation of China(No.99JA0002).
文摘Based on the study of the meshing theory of a new silent chain and sprockets, and the rolling cutting theory of sprocket and hob, the harmonious relations of dominating dimensions among the new silent chain, sprocket and hob is build, the meshing conditions are expatiated, and the resolved expression, which can instruct design and calculation, is educed. The tests show that the meshing design method is feasible.
基金supported by the National Natural Science Foundation of China (No. 51475460)
文摘To improve the cutting performance of an hourglass worm gear hob and the accuracy of the resulting worm gear,the rake angles of the teeth on the pitch circle should be reduced.A method of forming the spiral flutes by using a variable transmission ratio was developed.This method ensures that the rake angles on the indexing torus of each tooth are approximately 0°.Based on the gear meshing theory and the hourglass worm forming method,the discretization mathematical model of the rake face of a planar double enveloping worm gear hob was established by using cylindrical generating surface,and the feed parameters for machining the rake face for a variable transmission ratio were obtained.The spiral flute was simulated and the hob was machined on a four axis CNC milling machine.A contourgraph was used to measure the rake angle.The measurement results showed that the proposed method can reduce the absolute value of the rake angle on both sides of the cutting teeth,which can be used for machining the spiral flute rake face of an hourglass worm gear hob.
基金This project is supported by Colleges and Universities Doctor Subject Special Science Foundation of China(No.20020611004)National Natural Science Foundation of China(No.50575232).
文摘A variable inertial damper, whose viscous damping coefficient can be adjusted by changing the gap between inertia wheel and motor spindle, is designed in servomechanism of zero-drive hobbing machine and is directly attached on the motor spindle. The mathematical model of servo system with inertial damper is built. By using theoretical analysis and system simulation, it is demonstrated that the variable inertial damper with optimal damping coefficient and moment of inertia should lead to no resonance point in wider frequency range of exciting force. Therefore, its application in zero-drive hobbing machine makes this system not only achieve higher system stiffness to overcome load torque fluctuation, but also gain better stability.
文摘The wear and destruction appearances of hobs are researched. The reasons ofthe wear and destruction of hob are analyzed. And the influence of the change of the hobbing forceand the hobbing temperature on the wear and destruction of hob in gear hobbing is also analyzed. Ingear hobbing, the main wear mechanisms are adhesion and ploughing when cutting the 20CrMnTi gearusing W18Cr4V high-speed steel hob.
基金Supported by National Natural Science Foundation of China(Grant Nos.52075142 and U22B2084).
文摘The current research on noncircular hobbing mainly focuses on the linkage model and motion realization.However,the intermittent cutting characteristics of hobbing would increase uncertainties in the manufacturing process.In this paper,a hobbing machining model with tool-shifting characteristics was proposed to solve the problems of cutting force fluctuation and inconsistency of tooth profile envelope accuracy at different positions of the pitch curve in noncircular gear hobbing.Based on the unit cutting force coefficient method,the undeformed chip volume generated by interrupted cutting was used to characterize the fluctuation trend of the hobbing force.The fluctuation characteristics of the cutting force generated by different hobbing models were compared and analyzed.Using the equivalent gear tooth and hob slotting numbers,an analysis model of the tooth profile envelope error of the noncircular gear was constructed.Subsequently,the tooth profile envelope errors at different positions of the pitch curve were compared and analyzed based on the constructed model.The transmission structure of the electronic gearbox was constructed based on the proposed hobbing model,and the hobbing experiment was conducted based on the selfdeveloped noncircular gear CNC hobbing system.This paper proposes a hobbing method that can effectively suppress the fluctuation of the peak and whole circumference cutting force and reduce the maximum envelope error of the whole circumference gear teeth.
文摘This paper takes the escapement plate of a mechanical pendulum clock as an example,analyses the design of combination form cutter hob for special profile gears, selection of parameters and calculation for tooth profile coordinates and discusses the grinding of cutter hob tooth profile on optical contour grinder.
基金supported by The Development of Design and Manufacturing Technology of Double-Enveloping Worm Pair in High-precision with Little Centre Distance(No.69190135)We would like to thank the Professor Workstation of China Agricultural University in Hebei Baoding Laibo Transmission Machinery Manufacturing Co.LTD(No.20200901).
文摘The top relief surfaces of an hourglass worm gear hob are ground manually in the traditional manufacturing process,which cannot ensure the width of the land surfaces of the hob.Moreover,each geometric feature of the hob has been produced through different manufacturing techniques and machine tools,which results in low efficiency.To solve this problem,we propose a semi-automatic computer aided design(CAD)method for hobs.The point clouds of each feature surface of a hob are calculated by combing mathematical equations of the top relief surfaces built by the proposed method with other existing equations of hob surfaces.According to the point clouds,the method can achieve the automatic modeling for the hob in three-dimensional(3D)software by classifying and extracting the parameter information of the feature-hierarchical knowledge of the hob.Based on the generated 3D model,the entire surfaces of the hob can be manufactured on a four-axis computer numerical control(CNC)milling machine through only twice clamping.Verification of the width of the land surface of the hob manufactured by semi-automatic CAD method on a measuring projector proved the precision of the designed width can be ensured.The edge of the contact area on the worm wheel in a meshing experiment is clear and distinct,which means the worm gear drive is meshed well and the hob manufactured by the proposed method has improved machinability.The method simplifies the processing technique,and improves the design efficiency and production accuracy.
