文献翻译用PLC模块控制3轴数控铣床制造加工螺旋锥齿轮.docx
- 文档编号:3471497
- 上传时间:2022-11-23
- 格式:DOCX
- 页数:22
- 大小:1.52MB
文献翻译用PLC模块控制3轴数控铣床制造加工螺旋锥齿轮.docx
《文献翻译用PLC模块控制3轴数控铣床制造加工螺旋锥齿轮.docx》由会员分享,可在线阅读,更多相关《文献翻译用PLC模块控制3轴数控铣床制造加工螺旋锥齿轮.docx(22页珍藏版)》请在冰豆网上搜索。
文献翻译用PLC模块控制3轴数控铣床制造加工螺旋锥齿轮
外文资料翻译
UseofPLCmoduletocontrolarotarytabletocutspiralbevelgearwiththree-axisCNCmilling
S.Mohsen.Safavi,S.Saeed.Mirian,RezaAbedinzadeh,Mehdi.Karimian
Abstract
CNCmachiningnowadaysmakesmoreuseof“Mechatronics”increasingly.Combiningnumericalcontrolwithmechanic,electric,anddataprocessingsystemscanleadtonewmethodsofproduction.Inrecentyears,thedevelopmentofCNChasmadeitpossibletoperformnonlinearcorrectionmotionsforthecuttingofspiralbevelgears.Inthispaper,weattempttomanufacturethespiralbevelgearusingathree-axisCNCmillingmachineinterfacedwithanadditionalPLCmodulebasedontraditionaldiscontinuousmulticuttingmethodaccomplishedbyusingauniversalmillingmachineinterfacedwithanindexingworkhead.Thisresearchconsistsof(a)geometricmodelingofthespiralbevelgear,(b)simulatingthetraditionalandournewnontraditionalmethodusingaCAD/CAEsystem,(c)processplanningforCNCmachiningandPLCProgramming,(d)experimentalcutswithathree-axisCNCmillingmachineweremadetodiscoverthevalidityofthepresentedmethod.TheresultsdemonstratethatinventedexperimentalcuttingmethodofSBGsnotonlyislessexpensivethanadvancedCNCmachiningbutalsoproducesgearsinashortertimeincomparisonwiththetraditionalcutting.Thereby,itisaneconomicalmethodinmanufacturingofSBGs.
Keywords:
Gearmanufacturing.Spiralbevelgear.CAD/CAM/CAE.CNC.PLC.ACmotor.Inverter.Proximitysensors.Photoelectricsensors.Rotaryencoder
1Introduction
Gearsareimportantandprecisionmechanismsforindustrialmachineryasameansformechanicalpowerormotiontransmissionbetweenparallel,intersectingandnonintersectingcross-axisshafts.Althoughhiddenfromsight,gearsareoneofthemostimportantmechanicalelementsinourcivilization.Theyoperateatalmostunlimitedspeedsunderawidevarietyofconditions.Themachinesandprocessesthathavebeendevelopedforproducinggearsareamongthemostexistingingeniousones.Whetherproducedinlargeorsmallquantities,incell,orjobshopbatches,thesequenceofprocessesforgearmanufacturingrequiresfoursetsofoperations[1]:
1.Blanking
2.Gearcutting
3.Heattreatment
4.Grinding
Dependingontheirtypeandapplicationorrequiredstrengthandresistance,gearsaremanufacturedbycasting,extruding,forging,powdermetallurgy,plasticmolding,gearrolling,andmachining.Amongtheseprocesses,machiningismorefrequentlyusedforhigh-precisegears[2].Amongthevarioustypesofgears,thespiralbevelgears(SBG)arethemostcomplextypeandareusedtotransmittherotationalmotionbetweenangularlycrossedshafts.SBGshaveteethcurvedlongitudinallyalongthelengthoftheteeth.Themainadvantageofthesegearsoverthestraight-toothedvarietiesliesinthefactthatmoreteethareincontactatthesametimebecauseofthecurve-shapedcontouroftheteethandsoasmoothermeshingactionbetweenthematingpairisensured[3].Thedesignandmanufacturingofspiralbevelgearsisstillahottopicofresearchthatisvitaforapplicationofsuchgearsinhelicoptertransmissions,motorcyclegears,reducers,andinotherbranchesofindustry.Asfarasmanufacturingisconcerned,thegearsaremachinedbyaspecialtypeofmachinetools,suchasgearhobbingandshapingmachines.Recently,specialCNC-basedgearmanufacturingmachinetoolsareusedinindustrialpractice.Thismaybewhyliteratureongearmanufacturingissparseintheopenresearchdomain.Recently,CNC-basedgearmanufacturingmachinetoolshavebeendevelopedandincreasinglyusedinindustrialpractice.However,theirkinematicstructureisstillinherentlydifferentfromtheindustrialCNCmillingmachine,astheformerisdesignedforaspecialtypeofcutter.
Previousstudiesongearshavebeenmainlyconcernedwiththedesignandanalysisofgears.Thegeometriccharacteristicsanddesignparametersofgearshavebeenstudied[4-8].TsaiandChin[4]presentedamathematicalsurfacemodelforbevelgears(straightandSBGs)basedonbasicgearingkinematicsandinvolutesgeometryalongthetangentplanes.Later,thismethodwascomparedwithanothermodelbasedonexactsphericalinvolutescurvesbyAl-Daccaetal[5].Shunmuganetal.[6,7]presentedadifferentmodel,anditsaccuracy(comparedwiththespiralbevelgearmanufacturedbyspecialmachinetools)wasverifiedintermsofnominaldeviation.
Forcrowngears,afewresultsareavailable.LitvinandKim[8]suggestedagenerationmethodforaninvolutecurvefromamodifiedbasecircleforaspurgear.Umeyama[9]designedastandardprofileatthepitchcircleandamodifiedprofileatthetop/bottomfacegearwithadeterminationofthemodificationvaluefortransmissionerrorofhelicalgear.Tamuraetal.[10,11]studiedapointcontactmodelforabevelgearusingaflatsurfacetooth.Thesestudiesareconcernedwiththegenerationofthetoothprofileforspecialgearmachines,suchasgearhobbingandshapingmachines,whicharespeciallydesignedformanufacturinggears.Suhetal.[12]investigatedthepossibilityofasculpturedsurface-machiningmethodforthemanufactureofspiralbevelgearsandverifiedthepossibilitybypresentingtool-pathgenerationusingafour-axisCNCmillingmachineinterfacedwitharotary-tilttable.Amodel-basedinspectionmethodforthespiralbevelgearswasalsopresented[13].
Inthispaper,weattempttopresentanewmanufacturingprocedureofSBGsbyusingathree-axismillingmachineinterfacedwithaPLCmodulewhichoperatesasanindexingtable.Intermsofproductionrate,itisobviousthatthismethodwillbelowerthanthatofthespecialmachinetool.Otherthanproductionrate,thismethodisadvantageousinthefollowingrespects:
(1)theconventionalmethodrequiresalargeinvestmentforobtainingvariouskindsofspecialmachineryandcuttersdedicatedtoaverylimitedclassofgearsintermsofgeartype,size,andgeometry;
(2)bythismethod,varioustypesofgearscanbemanufacturedwiththeindustrialthree-axisCNCmillingmachine;(3)thismethodismoreeconomicalthanusingthespecialmachinetool.Oneofthemainpointswhichseparateourworkfrompreviousonesisdevelopinganautomaticcomputermodelinordertosimulatetheprocessentirelyandobtainmachiningparameter.Allpreviousstudieshavebeenengagedincalculatingcomplicatedmathematicalequationsanddesigninggeometricmodels.Inviewoftheabove,specialattentionisgiventoexperimentaltestsratherthanpresentinggeometricalormathematicalmodelofSBGs.Thisisthefirsttimethatmechatronicstoolsandathree-axisCNCmillingmachinearebeingusedsimultaneouslyinmanufacturingaspecialgearandevenamechanicalelement.
2Geometricspecificationsofthespiralbevelgears
Mostofthetime,thegeometricparametersofagearareprovidedwithanengineeringdrawing.Someparameters(principalparameters)arerequiredfordefiningthegeometry.Figure1showsmodule,spiralangle,andnumberofteethofgear.Table1summarizestheseparametersincludingrelationshipsamongparametersforthegearwhichhasbeenmanufacturedinourtest.Tocalculatetheseparameters,wehaveused“drivecomponentdevelopmentsoftware”calledGearTrax.
Thedesignofspiralbevelgearrequireshigh-accuracymathematicalcalculations,andthegenerationofsuchgeardrivesrequiresnotonlyhigh-qualityequipmentandtoolsformanufacturingofsuchgeardrivesbutalsothedevelopmentofthepropermachine-toolsettings.Suchsettingsarenotstandardizedbuthavetobedeterminedforeachcaseofdesign(dependingongeometricparametersofthegeardriveandgeneratingtools)toguaranteetherequiredqualityofthegeardrives.
3ManufacturingtheSBG
Asitwasdiscussedintheintroduction,bymachining,alltypesofgearscanbemadeinallsizes,andmachiningisstillunsurpassedforgearshavingveryhighaccuracy.Formmillingisoneofthemostcommonmachiningprocessesusedtomanufactureanytypesofgears[14].Thecutterhasthesameformasthespacebetweenadjacentteeth.Standardcuttersusuallyareemployedinform-cuttinggears.IntheUSA,thesecutterscomeineightsizesforeachdiametralpitchandwillcutgearshavingthenumberofteethindicatedinstandardtables.
Gleasonworksusedthefacehobbingprocessthatisbasedonthegeneralizedconceptofbevelgeargenerationinwhichthematinggearandpinioncanbeconsideredrespectively,generatedbythecomplementarygeneratingcrowngears[15].ThetoothsurfacesofthegeneratingcrowngearsarekinematicallyformedbythetracesofthecuttingedgesofthetoolbladesasshowninFig.2.
AsitisshowninEq.1,velocityratiooffacehobbingprocessdependsontoothnumberoftoolandgeneratinggear:
(1)
Where,
and
denotetheangularvelocitiesofthetoolandgeneratinggear;
and
denotethenumberofthebladegroupsandthetoothnumberofthegeneratinggear.
TheradiioftherollingcirclesofthegeneratinggearandthetoolaredeterminedbyEqs.2and3:
whereisthemachineradialsetting.
Thegeneratingcrowngearcanbeconsideredasaspecialcaseofabevelgearwith90°pitchangle.Therefore,agenericterm“generatinggear”isused.Theconceptofcomplementarygeneratingcrowngearisconsideredwhenthegeneratedmatingtoothsurfacesofthepinionandthegearareconjugate.Inpractice,inordertointroducemismatchofthematingtoothsurfaces,thegeneratinggearsforthepinionandthegearmaynotbecomplementarilyidentical.Therotationofthegeneratinggearisrepresentedbytherotationofthecradleonahypoidgeargenerator(Fig.3).
Toman
- 配套讲稿:
如PPT文件的首页显示word图标,表示该PPT已包含配套word讲稿。双击word图标可打开word文档。
- 特殊限制:
部分文档作品中含有的国旗、国徽等图片,仅作为作品整体效果示例展示,禁止商用。设计者仅对作品中独创性部分享有著作权。
- 关 键 词:
- 文献 翻译 PLC 模块 控制 数控 铣床 制造 加工 螺旋 齿轮
![提示](https://static.bdocx.com/images/bang_tan.gif)