10.24423/EngTrans.1525.20230110
Tool Path Planning for Five-Axis End Milling of Cycloidal Gears and Its Full Tooth Profile Accuracy Measurement
This paper proposes a method of end milling of cycloidal gears using a five-axis computer analytical control (CNC) machine tool. Firstly, the basic principle of the five-axis end milling of cycloidal gears is introduced. The cutting characteristics of the ball-end and the flat-end cutters are analyzed. Secondly, the path planning method of the five-axis end milling of cycloidal gears is researched. A curvature matching method is used to check for local over-cut interference and a minimum distance method is used to check for global collision interference. These two interferences are avoided by calculating the feasible range of cutter orientations and adjusting the dips of cutter shafts. Tests of end milling of cycloidal gears are carried out using a ball-end cutter and a flat-end cutter, respectively. Finally, full tooth profile accuracy measurements are undertaken with an image-measuring instrument to assess the quality of cycloidal gears processed in this way. This study provides a theoretical basis for the improvement of the tooth profile accuracy and surface quality of cycloidal gears.
Copyright © The Author(s). This is an open-access article distributed under the terms of the Creative Commons Attribution-ShareAlike 4.0 International (CC BY-SA 4.0).
References
Li T., Li J., Deng X., Tian M., Li Y., Quantitative correction method for the grinding errors of cycloidal gears in precision reducer, Journal of Advanced Mechanical Design, Systems, and Manufacturing, 14(4): JAMDSM0052, 2020, doi: 10.1299/jamdsm.2020jamdsm0052.
Jiang C., Wang H.L., Han T.H., Liu X., Simulation and compensation of axial geometric errors for cycloidal gears based on form grinding, Mathematical Problems in Engineering, 2022: 4804498, 2022, doi: 10.1155/2022/4804498.
Zhou B., Wang S., Fang C. Sun S., Dai H., Geometric error modeling and compensation for five-axis CNC gear profile grinding machine tools, The International Journal of Advanced Manufacturing Technology, 92(5): 2639–2652, 2017, doi: 10.1007/s00170-017-0244-y.
Zhang W., Wei X., Guo X., Tan R., Wang Y., A novel continuous indexing method for face-hobbed hypoid gear tooth grinding, Mechanism and Machine Theory, 173: 104826, 2022, doi: 10.1016/j.mechmach-theory.2022.104826.
Özel C., A study on cutting errors in the tooth profiles of the spur gears manufactured in CNC milling machine, The International Journal of Advanced Manufacturing Technology, 59(1), 243–251, 2012, doi: 10.1007/s00170-011-3475-3.
Bo P., González H., Calleja A., de Lacalle L.N.L., Bartoň M., 5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools. Part I: Modeling and simulation, Precision Engineering, 62: 204–212, 2020, doi: 10.1016/j.precisioneng.2019.11.015.
Lu Y.-A., Wang C.-Y., Smoothing method of generating flank milling tool paths for five-axis flat-end machining considering constraints, The International Journal of Advanced Manufacturing Technology, 110(11): 3295–3309, 2020, doi: 10.1007/s00170-020-05880-z.
Wu B., Liang M., Zhang Y., Luo M. Tang K., Optimization of machining strip width using effective cutting shape of flat-end cutter for five-axis free-form surface machining, The International Journal of Advanced Manufacturing Technology, 94(5): 2623–2633, 2018, doi:10.1007/s00170-017-0953-2.
Tang T.D., Algorithms for collision detection and avoidance for five-axis NC machining: a state of the art review, Computer-Aided Design, 51: 1–17, 2014, doi: 10.1016/j.cad.2014.02.001.
Li X. Ren J., Tang K., Zhou Y., A tracking-based numerical algorithm for efficiently constructing the feasible space of tool axis of a conical ball-end cutter in five-axis machining, Computer-Aided Design, 117: 102756, 2019, doi: 10.1016/j.cad.2019.102756.
Bajić D., Celent L., Jozić S., Modeling of the influence of cutting parameters on the surface roughness, tool wear and the cutting force in face milling in off-line process control, Strojniški vestnik – Journal of Mechanical Engineering, 58(11): 673–682, 2012, doi: 10.5545/sv-jme.2012.456.
Sun Y., Ren F., Zhu X., Guo D., Contour-parallel offset machining for trimmed surfaces based on conformal mapping with free boundary, The International Journal of Advanced Manufacturing Technology, 60(1): 261–271, 2012, doi: 10.1007/s00170-011-3577-y.
Zou Q., Robust and efficient tool path generation for machining low-quality triangular mesh surfaces, International Journal of Production Research, 59(24): 7457–7467, 2021, doi: 10.1080/00207543.2020.1842939.
Wu B., Zhang D., Luo M., Zhang Y., Collision and interference correction for impeller machining with non-orthogonal four-axis machine tool, The International Journal of Advanced Manufacturing Technology, 68(1): 693–700, 2013, doi: 10.1007/s00170-013-4791-6.
Wang G.X., Shu Q.L., Wang J., Wang W.S., Tool interference checking for 5-axis NC Machining of sculptured surfaces [in Chinese], China Mechanical Engineering, 25(3): 299–303, 2014.
Liu C., Li Y., Jiang X., Shao W., Five-axis flank milling tool path generation with curvature continuity and smooth cutting force for pockets, Chinese Journal of Aeronautics, 33(2): 730–739, 2020, doi: 10.1016/j.cja.2018.12.003.
Sato O., Osawa S., Kondo Y., Komori M., Takatsuji T., Calibration and uncertainty evaluation of single pitch deviation by multiple-measurement technique, Precision Engineering, 34(1): 156–163, 2010, doi: 10.1016/ j.precisioneng.2009.05.009.
Shi Z.Y., Kang Y., Gear pair integrated error and its measurement method [in Chinese], Journal of Tianjin University, 45(2): 128–134, 2012.
Shi Z.Y., Wang X.Y., Yu B., Shu Z.H., New method to determine the tooth profile evaluation area in gear integrated error measurement [in Chinese], Journal of Mechanical Engineering, 53(3): 34–42, 2017.
Ling S.Y., Wang L.D., Lou Z.F., Liu Q., Zhao Y.W., Error compensation of the measurement position in ultra-precision gear pitch deviation measurement [in Chinese], Chinese Journal of Scientific Instrument, 35(3): 691–696, 2014.
Xu B., Shimizu Y., Ito S., Gao W., Pitch deviation measurement of an involute spur gear by a rotary profiling system, Precision Engineering, 39: 152–160, 2015, doi: 10.1016/j.precisioneng.2014.08.003.
Wang X.Y., Shi Z.Y., Lin J.C., Fast measurement method for pitch deviation based on full tooth profile information [in Chinese], Chinese Journal of Scientific Instrument, 37(10): 2202–2210, 2016.
Zhou J.J., High Efficiency and Accuracy Machining of Complex Surfaces [in Chinese], Zhejiang: Zhejiang University Press, 2014.
DOI: 10.24423/EngTrans.1525.20230110