Manufacturing Method of Large-Sized Spiral Bevel Gears in Cyclo-Palloid System Using Multi-Axis Control and Multi-Tasking Machine Tool

摘要

The large-sized spiral bevel gears in a Klingelnberg cyclo-palloid system are manufactured using multi-axis control and a multi-tasking machine tool. This manufacturing method has its advantages, such as arbitrary modification of the tooth surface and machining of the part minus the tooth surface. The pitch circular diameter of the gear treated in this study is more than 1,000 mm (approx. 40"). For this study, we first calculated the numerical coordinates on the tooth surfaces of the spiral bevel gears and then modeled the tooth profiles using a 3-D CAD system. We then manufactured the large-sized spiral bevel gears based on a CAM process using multi-axis control and multi-tasking machine tooling. After rough cutting, the workpiece was heat treated and finished by swarf cutting (Ed.'s note: The removal and cutting of metal in which the axis of the cutting tool is varied with respect to the part being machined) using a radius end mill. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. Moreover, the gears were meshed with each other and the tooth contact patterns were investigated. As a result, the validity of this manufacturing method was confirmed.