Machining Methods Of Orthogonal Variable Transmission Ratio Curve-face Gear

The orthogonal variable transmission ratio Curve-Face gear drive is a transmission in which a non-circular gear engages with a Curve-Face gear. Motion and the power of intersecting axes can be transferred by this gear pair, which has the characteristics of variable gear ratio transmission. At present, the face gear drive machining complex, as a result, the development and application of the gear drive is restricted. Therefore, it is very important to study machining methods of the face gear drive.This issue derives from Natural Science Foundation of China(51275537), to analyze transmission characteristic and explore processing and manufacturing methods of Curve-Face gear drive, finally, the experiment is performed to verify the feasibility of design principle and processing method. In the thesis, the research work has been organized aiming at Curve-Face gear drive as following:According to the gear meshing theory, cutter tooth profile and conjugate principle, Gear design principle, the modern design method, the basic transmission theory and meshing coordinate were studied and proposed. The gear root cutting phenomenon was studied, the minimum inner diameter was calculated, and root cutting condition, transmission ratio, angular displacement and angular velocity characteristics of the face gear drive were analyzed. The model of face gear drive is built combined with VB and Solidworks, and smooth processing is done to the tooth surface. Modal analysis of the face gear drive was analyzed by using ANSYS, The first six order natural frequency was obtained.By the space gear meshing theory, the basic principle of multi-axis CNC machine tool, envelope method, the milling principle, advanced manufacturing technology, the principle of work piece positioning and clamping, tooth surface detection principle, the roll test technology and test bench test system theory, the spatial coordinates of the tool and the non-circular gear, processing coordinate system of Curve-Face gear, addendum fillet model, contact line model, AM machining model and CNC machining model are established.The process and method of fabricating curve-face gear using AM and five-a xis CNC machine were studied. The contacting line in the simulated fabrication model was analyzed. The second locating analysis for the AM of curve-face gear was conducte d. The pitch error test, the accumulated pitch error test, the tooth profile error test, roll e xperiment and the test bench experiment were conducted for the curve-face gear pair. The coordinate transformation matrices from the tool to the noncircular gear and from the noncircular gear to the curve-face gear, the transitional surface equations and the motio n matrix of the tool during processing were obtained. The methods for the multi-axis C NC machining of curve-face gears, the processing of face gear along contacting line, co mbined processing of curve-face gear using additive manufacturing and five-axis CNC machining, the bias cutting model for gear pairs, errors on tooth surface, contacting imp rint and motion characteristics data of gears were also obtained. The correctness of the design for the curve-face gear pair and three methods of fabricating curve-face gears we re verified.