基于四轴运动简化模型的成形磨齿齿向修形

Flank line modification of gear profile grinding based on a four-axis motion simplified model

  • 摘要: 成形磨齿常用附加径向运动、附加转角运动和附加径向加转角运动等齿向修形方法,齿面扭曲误差大,而五轴附加运动方法优化迭代过程复杂,稳定性差。针对这些问题,提出一种四轴附加运动简化模型实现齿向鼓形修形优化。模型在传统方法上增加了附加切向运动(Y轴)构成XYZC四轴附加运动方法,以有效消减双齿面磨削扭曲误差,同时采用3阶多项式描述各联动轴运动轨迹,低阶多项式模型可大幅降低矩阵求解计算量并提升迭代稳定性。在迭代优化过程进一步引入了改进Levenberg-Marquardt (L-M)算法克服矩阵奇异性无解问题,稳定附加运动求解计算。理论分析与实际加工实验表明,所提方法可有效消减斜齿轮齿向修形时出现的齿面扭曲误差,保证磨齿修形精度。

     

    Abstract: Flank line modifications on a form grinding machine include several traditional methods, such as additional radial motion, additional angular motion, and combined radial and angular motion, which inherently have a large flank twist. In contrast, the five-axis additional motion optimization iterative process is complex and exhibits poor stability. To address these issues, a simplified four-axis additional motion model is proposed to optimize the helical profile modification for typical crowning. The model supplements additional tangential motion (Y-axis) to form a four-axis linkage comprising X, Y, Z, and C, to control the twist errors of double flank form grinding. Meanwhile, third-order polynomials are used to describe the motion of each axis. The low-order polynomial model can significantly reduce the matrix solution calculation and improve iterative stability. The improved Levenberg-Marquardt (L-M) algorithm is introduced in the iterative optimization process to avoid singularity and the non-solution problem of the matrix, thereby stabilizing the additional motion solution calculation. Theoretical analysis and actual grinding experiments demonstrate that the proposed method effectively reduces tooth surface twist errors during the modification of helical gear tooth profiles and ensures the accuracy of the grinding modification.

     

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