插齿机-功能原理设计参考

目录

概述 (2)

一、系统的功能原理设计 (4)

（一）、功能的定义及分类 (4)

（二）、功能原理设计 (4)

（三）、功能原理设计的设计方法——黑箱法 (7)

（四）、功能结构 (18)

二、结构总体设计 (20)

（一）、结构总体设计的任务、原则 (20)

（二）、总体布置设计 (23)

（三）、总体布置设计的基本要求 (23)

三、插齿机三维图 (24)

四、参考文献 (28)

致谢 (29)

概述

齿轮齿间的空间形状是复杂的，而且随着齿轮的齿数和模数的不同而变化，因此大多数的齿轮制造方法采用斩成齿廓而不是成形加工。这种制造方法叫仿形法，包括刨削和插削两种加工方法。

刨削采用往复运动的齿条刀，当齿条刀实际上绕齿轮坯料滚切并沿其螺旋线方向运动时，齿形就会被逐渐展成。插削加工在本质上与刨削加工类似，只是采用了圆形刀具来取代齿条刀。其结果是减少了往复运动惯性，在加工过程中可以采用比刨削高得多的行程速度。现代插齿机在加工汽车齿轮时可以达到每分钟2000次切削行程。插齿刀的形状与渐开线齿轮大致相同，但是其齿顶是圆的。

由于刀具与工件之间的展成传动只包括圆周运动，因此不需要齿条或者丝杠。在刀具的每一次行程中，通常刀具和工件的切向移动距为0.5mm。在回程中，道具必须退让1mm以留出间隙。否则，在退刀时，刀具会擦伤已加工表面，并且加快刀具的磨损。

插齿加工的优点是生产效率较高和可以将齿插到接近轴肩处。令人遗憾的是，加工斜齿轮时需要有一个能够生产绕齿运动行程本身旋转的螺旋导轨。这种螺旋导轨不易制造，或者说其制造成本较高。由于对每一种不同螺旋角的齿轮，应该制造不同参数的插齿刀和螺旋导轨，因此这种方法仅适用于斜齿轮的大批量生产加工。插削加工的一大优点是能够加工诸如大型行星齿轮传动所需要的内齿轮。

Summary

The shape of the space between gear teeth is complex and varies with the number of teeth on the gear as well as tooth module, so most gear manufacturing methods generate the tooth flank instead of forming. This method that we called tooth flank include in planing and shaping.

Planing uses a reciprocating rack, stroking in the direction of the helix on a gear with a gradual of form as the rack effectively rolls round the gear blank.

Shaping is inherently similar to planing but uses a circular cutter instead of a rack and the resulting reduction in the reciprocating inertia allows much higher stroking speeds; modern shapers cutting car gears can run at 2 000 cutting strokes per minute .The shape of the cutter is roughly the same as an involute gear but the tips of the teeth are rounded.

The generating drive between cutter and workpiece does not involve a rack or leadscrew since only circular motion is involved. The tool and workpiece move tangentially typically 0.5 mm for each stroke of the cutter. On the return stroke the cutter must be retracted about 1 mm to give clearance otherwise tool rub occurs on the back stroke and failure is rapid.

The advantages of shaping are that production rates are relatively high and that it is possible to cut right up to a shoulder. Unfortunately, for helical gears, a helical guide is required to impose a rotational motion on the stroking motion; such helical guides cannot be produced easily or cheaply so the method is only suitable for long runs with helical gears since special cutters and guides must be manufactured for each different helix angle. A great advantage of shaping is its ability to cut annular gears such as those required for large epicyclic drives.