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数控卧式镗铣床主轴箱变速操纵机构设计,数控,卧式,铣床,主轴,变速,操纵,机构,设计

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毕业设计(论文)中期报告题目：数控卧式镗铣床主轴箱变速操纵机构设计系 别 机电信息系 专 业 机械设计制造及其自动化 班 级 姓 名 学 号 导 师 2013年3月20日1 设计（论文）进展状况本阶段的主要任务是完成了外文文献NEW GEOMETRY AND TECHNOLOGY OF FACE-GEAR FORMING WITH CIRCLE LINE OF TEETH ON CNC MILLING MACHINE翻译，对主轴箱进行了更深层次的分析和理解，通过分析，主轴箱主传动系统采用变速齿轮进行调速，是利用液压拨叉波动滑移齿轮到达所需要的位置来实现的。如图1所示。图1 主轴箱变速操纵机构装配图1.1电动机的选取1.1.1选择电动机的类型根据用途选用Y系列一般用途的全封闭自冷式三相异步电动机，三相异步电动机的结构简单、价格低廉、维护方便，可直接接于三相交流电网中，在工业上用途最为广泛，具有效率高、性能好、噪声低、振动小等优点，适用于不易燃、不易爆、无腐蚀性气体和无特殊要求的机械上，如金属切屑机床。1.1.2 转速及功率的确定初步选定电动机功率为7.5kW。一般市场上最常用、供应最多的是同步转速为1500r/min和1000r/min的电动机，无特殊需求不选用3000r/min和750r/min的电动机，因此选择1500r/min的电动机，其满载转速为1440r/min.1.2 联轴器的选择联轴器的选择应由工作要求决定。由于输入轴与电动机轴直接相连，并且转速高，转矩小，所以选用弹性套柱销联轴器。1.3 各齿轮齿数及相关参数的确定表1所示为初步确定各齿轮的齿数及相关参数：表1 各齿轮的齿数及相关参数编号齿数模数材料热处理齿轮127340CrG48齿轮245340CrG48齿轮323340CrG48齿轮438340CrG48齿轮567340CrG48齿轮652340CrG48齿轮753440CrG48齿轮822440CrG48齿轮935440CrG48齿轮1060440CrG481.4 转速的计算在初步确定齿轮的齿数的情况下，计算主轴的转速。齿轮5、6和齿轮7、8为两个双连齿轮并安装在同一根轴上，齿轮2、3、4安装在另一根轴上，齿轮9和齿轮10安装在主轴上。从电动机输出，经过齿轮传动到主轴有4中转速，分别为：230r/min、950r/min、110r/min、450r/min。轴1的转速是由电动直接输出的，所以转速为1440r/min,轴2和轴3的转速是由齿轮传递的，所以轴2的转速为1440*27/45=864r/min，轴3的转速有两种分别为864*38/52=631.38r/min和864*23/67=296.6r/min。1.5各轴功率计算轴1功率为P1=7500*0.99*0.99=7350.75W；轴2功率为P2=P1*0.97*0.99=7056W；轴3功率为P3=P2*0.97*0.99=6779W；主轴功率为P0=P3*0.97*0.99=6510W。1.6 转矩的计算轴1的转矩为T1=9549*7350.75/1440=48.7N*m；轴2的转矩为T2=9549*7056/864=77.98N*m；轴3有转矩有两种，分别为102.53N*m和218.25N*m；主轴有四种转矩，分别为270.28N*m、65.44N*m、565.13N*m、138.14N*m。1.7 齿轮的主要尺寸的设计计算在齿轮的设计计算中，主要计算了齿轮的齿宽，齿顶圆半径，齿根圆半径，并且对齿轮进行强度校核。轮毂直径是根据所安装的轴的直径确定的。1.8 轴的主要尺寸的设计计算在轴的设计计算中，主要计算了轴的总长度，以及各段轴的轴径和长度。首先初步估算轴的直径，按照扭转强度初步计算的轴径为最小直径，有键槽处直径增大3%。然后进行圆整，最后进行强度校核。2 存在问题及解决措施由于毕业设计涉及的范围很广，几乎囊括了在大学里所学的全部知识，很多在大一、大二学习的知识由于很久没有接触造成了这些知识的模糊甚至淡忘，所以在某些细节方面总是会有多多少少的问题，给设计带来了不小的麻烦。下面是我设计过程中遇到的问题以及解决方案。2.1 存在问题及解决措施问题1 所选的电动机和联轴器是否符合要求？在设计过程中，我查阅了很多资料，看了老师给的图册，和同学讨论以及通过综合计算之后最终确定了所选用的电动机和联轴器。问题2 确定的齿轮的齿数和各参数是不是合理？通过查阅相关书籍，网上搜索以及和同学探讨后，最终确定了最合理的各齿轮齿数和参数以及热处理的方法。问题3 总体的结构设计计算。在设计中，通过老师给的图册，查阅相关文献，确定了主轴箱的总体结构，其中包括箱体的壁厚以及肋的厚度。3 后期工作安排（1）完成详细的设计计算；（2）根据计算的数据画出零件图和装配图；（3）编写设计说明书以及校核图纸，交给导师查阅；（4）整理资料，准备答辩。指导教师签字： 年 月 日109METALURGIJA 51 (2012) 1, 109-112P. FRCKOWIAK, W. PTASZYSKI, A. STOI NEW GEOMETRY AND TECHNOLOGY OF FACE-GEAR FORMING WITH CIRCLE LINE OF TEETH ON CNC MILLING MACHINEReceived - Prispjelo: 2011-02-27Accepted - Prihvaeno: 2011-04-20Preliminary Note Prethodno priopenjeISSN 0543-5846METABK 51(1) 109-112 (2012)UDC UDK 621.833:621.914.3.744=111Diff erent types of geometric models of face-gear with circle line of teeth have been shown in the paper. Generation of a new geometrical of a face-gear is performed on CNC milling machine. The basic direction of the development geometrical of a face-gear and technology is in the search of new trends and methods focused on improving the quality of products, shortening the production cycles, their mechanizations, automation and implementation of a high-precision technology. Key words: face-gear, circular line, CNC milling-machineNova geometrija i tehnologija oblikovanja hipoidnih zupanika na CNC glodalici. Razliiti tipovi geometrijskih modela hipoidnih zupanika su prikazani u radu. Izrada novog geometrijskog oblika zupanika je provedena na CNC glodalici. Temeljni smjer razvoja geometrijskih oblika zupanika i tehnologije izrade je u traenju novih tren-dova i metoda za unaprjeenje kvalitete proizvoda, skraenja trajanja proizvodnog ciklusa, njegova mehanizacija, automatizacija iimplementacija visokoprecizne tehnologije.Kljune rijei: zupanik, kruna linija, CNC glodalicaINTRODUCTIONInvention of face worm gear drives with conical and cylindrical worms by Saari 1, 2 was a substantial con-tribution. Initially the design of the invented gear drives was based on application of worms provided by axial profi les as straight lines 3. The generation of face worm gear drives of all types of existing design is based on application of a hob for generation of the face-gear. The disadvantage of such method of generation is the low precision of a hob used as a generating tool espe-cially in the case of small dimensions of hob 3. The generations of a face worm gear drives of all types of existing is based on application of a hob for generation of the face worm gear with conical and cy-lindrical worms. Saari 1, 2 and next researchers had proposed methods based on application a worm hob for manufacturing a face worm gear with conical or cylin-drical worms. Litvin and coworkers 3 had proposed a tilted head-cuter for forming of face worm gear drives with conical and cylindrical worms. In work 4-10 and 11 presented developed a new technique of cutting a face worm gear on a CNC machining. For generation face-gear used the 4-axis vertical CNC milling-machine incorporate a rotary table and a NC spindle. The new process uses general purpose machine like vertical ma-chining centre. The generations are performed by a tilt-ed tool edge with straight line profi les of blades. The P. Frckowiak, W. Ptaszyski , Institute of Mechanical Technology, Poznan University of Technology, Poznan, PolandA. Stoi, University of applied sciencies, Slavonski Brod, Croatiaprocess is giving better results with use of newly devel-oped technique to generate a face-gear. Due to addition two rotational axes in 5-axis machining enables cutting face-gear and taken high surface quality.For numerically controlled universal milling-ma-chine a face-gear can be shaped with different front lines of teeth. Known methods for forming face-gear are based on kinematics of conventional machine tools. While notching the teeth, workgroups of machine per-forms movements at a constant speed, the tracks are rectilinear or rotary (NC rotary tables, spindle tool). One way to cut face-gear is the use of single blade tool in the form of a universal sintered carbide insert.This method may be used to shape the toothing of a straight and involute line of teeth 4-10, 11. The new geometry and technology proposed in this article is based on application of single blade tool and CNC mill-ing-machine with special program of control. MODELING FACE GEAR WITH CIRCLE LINE OF TEETH Figure 1 illustrates schematically the generation of the face-gear.In the following geometric models of shaping circle line, assumptions are that: a tooth line is shaped with single blade tool, a incision tooth line is rigidly linked to the ma-chined teeth crown, a beginning of the system of coordinates is located at the intersection of the axis of symmetry shaped toothing,110 METALURGIJA 51 (2012) 1, 109-112P. FRCKOWIAK et al.: NEW GEOMETRY AND TECHNOLOGY OF FACE-GEAR FORMING WITH CIRCLE LINE OF TEETH. the location of the curve, part of which is a tooth li-nes, is set in relation to the theoretical rolling circle, a trace location of the tool is described by the blade cutting edge is so located in relation to the shaped surface to have a common normal with the shaped line of the tooth.Here are models of geometrical shape of the tooth which is a circle, with different radii of curvature of the teeth line.In the simplest model of the toothing with circular line, the axis of symmetry of the circle, which is part of the line tooth, lies at the intersection of the theoretical rolling circle with a Rb radius and the axis of system coordinates associated with the shaped toothing (Z). The geometric model is shown in the Figure 2.From Figure 2 can be determined the coordinates of points in the ring-shaped toothing: ()()+=sincos11bRzx, (1)as well as ()()+=+=02202sinctgxzRxv, (2)where: radius of a circle of being the tooth line, Rb theoretical rolling circle.From the described model in Figure 1 it is possible also to set coordinates of points in polar coordinates: +=212110arcsinzxRRxvv. (3)Placing described relations to equations 2 with equa-tions 3 we receive: +=+=21211222121121212arcsinarcsinsinzxxctgxzzxxzxx (4)and after substituting formula 1 to equations 4 we re-ceive (5).Equations 5 describe the track of the tools in the forming process of toothing, the tooth-line as part of a circle with a radius. Variable in the division plane is an increase in the angle of rotation of toothing.Figure 1 Scheme the generation of the face-gearFigure 2 Geometric model of forming face-gear with circular line with symmetric axis of circle teeth line places on the axis of face-gearFigure 3 The geometric model of forming face-gear with circular line, the circle line of tooth with the axis of symmetry moved in the direction of positive X-axis values()()()()()()()()()()()+=+=222222222sincoscosarcsinsincoscosarcsinsinsincosbbbRctgxzRRxAnother solution toothing with a tooth line as a part of a circle is a circle line of tooth shift so that it does not lie on the Z-axis of face-gear. In the case of the circle line of tooth with the axis of symmetry moved in the direction of positive X-axis, in the toothing tooth lines can be obtained with less radius of curvature. Geomet-ric model of such a solution is shown in Figure 3.(5)111METALURGIJA 51 (2012) 1, 109-112P. FRCKOWIAK et al.: NEW GEOMETRY AND TECHNOLOGY OF FACE-GEAR FORMING WITH CIRCLE LINE OF TEETH.From the Figure 3 can be determined the coordinates of points in the ring-shaped toothing: ()()+=+=sincos111bcRzxx. (6)From Figure 3 it is possible to set coordinates of points like in case of the description of the model shown in Figure 2 (equations 2, 3, 4), and after placing relation 6 to equations 4 relations circumscribing the line of the tooth are (7).The xc1 value determines the location of the center of a circle line of teeth and the size of radius of curvature of the teeth line. In the case of xc1 = 0 circle line of tooth lies on the Z-axis of toothing. Addition of xc1 in the equation 10 reduces and subtracting of xc1 increases the radius of curvature of the circle.THE ALGORITHM OF STEERING AND EXPERIMENTAL EXAMINATIONS OF THE SYNCHRONIZATION OF STEERED AXIS OF THE MACHINE TOOL In order of conducting attempts to synchronize the axis of the machine tool enabling forming face-gear with circle line of teeth control algorithm was devel-oped as shown in Figure 5. This algorithm served to develop parameterized control program for the machine tool notching the teeth of toothing. Attempts to shape face-gear were conducted on the milling machine FYN - 50ND type, equipped with nu-merically controlled rotary table (Figure 6a). The mill-ing machine is holding the control system of the TNC 407 type of the Heidenhain.The Heidenhain 407 controller enables simultaneous interpolation in three axes (linear or circular in three di-mensional space). Steering of processing of the outline is held with digital speed control. Servo systems in each axis servo are position regulated type, controlled by de-viation signals. Feed the axes X, Y, Z and A are carried out by four independent pulse-controlled AC motors. The drive of the spindle is equipped with a system for con-tinuous variable speed transmission. In the axis of the spindle of the milling machine a rotational-pulse sensor was fastened, which signals are transmitted to the control system of the machine tool what allows to control spindle as a rotational axis (C). An example of cutting teeth line in the face-gear is shown at Figure 6b.CONCLUSIONSConducted examinations of the generation of the face-gear according to the relation described with for-mula 10 confi rmed the possibility of shaping the circle line teeth on the CNC milling-machine. Despite of heavy-load of processor with complex calculations con-trol system do not cause temporary detention of con-trolled machine tools units. The surveys are the basis ()()()()()()()()()()()()+=+=22112222112212sincoscosarcsinsincoscosarcsinsinsincosbccbccbcRxxctgxzRxxRxxWith alternative of moving the arrangement of the circle of the line of teeth of toothing is reallocating his middle is so that it is in negative values of the X-axis. Such moving the circle of the line of the tooth will al-low the tooth to obtain a larger radius of curvature of the tooth line. Geometric model of such a solution is shown in Figure 4.Relations result from Figure: ()()+=+=sincos111bcRzxx. (8)Taking equation 2 and 3 into consideration, it is also possible to derive on the basis of model 4 and after sub-stituting the equation to relation 4 describing the tooth line becomes (9).()()()()()()()()()()()()+=+=22112222112212sincoscosarcsinsincoscosarcsinsinsincosbccbccbcRxxctgxzRxxRxxIncluding models shown in Figures 2, 3 and 4 and equations of the teeth line described with relations 5, 7 and 9 it is possible to represent equations describing synchronizations of steered pivots of the machine tool generalized with relation (10).()()()()()()()()()()()()+=+=22112222112212sincoscosarcsinsincoscosarcsinsinsincosbccbccbcRxxctgxzRxxRxxFigure 4 The geometric model of forming face-gear with circular line, the circle line of tooth with the axis of symmetry moved in the direction of negative X-axis values(7)(9)(10)112 METALURGIJA 51 (2012) 1, 109-112P. FRCKOWIAK et al.: NEW GEOMETRY AND TECHNOLOGY OF FACE-GEAR FORMING WITH CIRCLE LINE OF TEETH.for further work on applying a face-gear with circle line of teeth in clutch connection.AcknowledgementThis paper is fi nanced from the funds for science for the years 20092012 granted by the Polish government and is referred to as the research project no N N502 339836.Legend of symbolsRi inner radius of the face-gearRb theoretical rolling circle Re outer radius of the face-gearX,Y,Z coordinate system connected to machine-tool x,z coordinate system rigidly connected to face-gearz number of teeth of the face-gear radius of generation a circle tooth line of face-gearC angle of rotation of the grinding tool A angle of rotation of the face-gear in the process of generation additional rotational motion of the face-gear dur-ing grinding tool motion P1,P2 points of contact on surface of tooth line and grinding tool trace xc1 parameter of relative location of point of the cent-er of the circle tooth line REFERENCES1 O. E. Saari, Speed-reduction gearing, Patent No. 2,696,125, United States Patent Offi ce, 1954.2 O. E. Saari, Skew axis gearing, Patent No. 2,954,704, Uni-ted States Patent Offi ce, 1960.3 Litwin F.L, A. Nava, Q Fan, A. Fuentes, New geometry of worm gear drives with conical and cylindrical worm: genera ti-on, simulation of meshing, and stress analysis, Comput. Methods Appl. Mech. Eng. 191, (2002) 3035-3054.4 Frckowiak P., Forming and geometrical dependences in the nom-homogeneous face-gear with involute line, Manu-facturing Engineering, 9 (2010) 4, 28-30. 5 Frckowiak P., Modelling and cutting a face-gear with straight line on CNC milling-machine, Manufactur