Generating processing method and tooth surface deviation characteristics of non-circular face gear based on disk cutter

Abstract

Non-circular face gear is a new type of gear with variable transmission ratio, which has the advantages of simple closure condition and good interchangeability. However, the lack of effective processing methods limits its application and development. A generating method using a disk cutter on a five-axis CNC machine was presented. According to the principle of gear shaping, the enveloping process of non-circular face gear using a disk cutter was explained and the linkage mathematical model of the machine tool was established. By analyzing the source of errors in the machining process, the tooth surface model of non-circular face gear with machining errors was established. The correctness of the processing method and mathematical model were verified by machining simulation. Furthermore, the influence of machining error on the tooth surface was analyzed by the tooth surface model. It is found that the X-axis and Z-axis error of the machine tool causes uniform deviation on the tooth surface, while the angle error around B-axis causes gradient distribution deviation from the top to the root on the tooth surface.

Keywords

• generating method
• non-circular face gear
• tooth surface model
• machining error