Research On Profile Error Modification And Quality Control Of The Constant-Depth Tooth Bevel Gear In Cutting Process

In the cutting process of constant-depth tooth gear,it is difficult to guarantee the quality and consistency of gear contact area,which is the key factor affecting the gear transmission noise because of the complexity of cutting processing and machine setting modifications.In the actual cutting process,the quality control of contact area is both a key point and a difficulty because of the hard tooth profile error modification.So the methods of modifying the tooth profile error and controlling the quality of contact area are studied in order to improve the quality and consistency of the contact area of the constant-depth tooth gear of the rear axle of a passenger vehicle.The main research results are as follows.(a)Based on the forming theory of the constant-depth tooth gear and the relations between the cutter,machine tool and gear coordinate systems,the gear tooth surface equation and tooth contact equation were deduced,while the measurement and modification principle of the tooth profile error was introduced to analyze the main factors that influence the tooth profile error.(b)The impact and influence coefficient of modification of single machine tool processing parameters on the tooth profile error were proposed here,where the key machine tool processing parameters on tooth profile error were found,and corresponding suggestions for tooth profile error modification were also provided.(c)Combined with the mathematical model of tooth surface with machine tool processing parameter adjustment,deviations between actual tooth surface and target of the tooth surface under different solving algorithms and gear modified methods are compared.It is concluded that the solving result of double dogleg algorithm is the optimal solution for tooth profile error modification,which can be verified by the practical cases.(d)A closed-loop measurement-modification-manufacturing model for tooth profile error control strategy is established,and an automatic identification system combining the gear measuring center,cutting machine and central computer was developed to judge the deviation type and calculate the corrected items of machine tool processing parameters.The closed-loop control system can be carried out effectively and improves the quality and efficiency of the gear cutting process.(e)Through the experimental study on the quality of machine tool and fixture error on gear cutting process,the key items detection standards were established,while the process of machine settings modifications is set up to control the contact area,and mesh the contact area with the standardized gear,thus improving the gear quality and consistency in cutting process.