Interference-Free Tool Path Generation for Milling of Spur Gears

doi:10.12068/j.issn.1005-3026.2022.07.011

Abstract

Abstract: Regarding the finish machining of multi-axis milling， an interference-free tool path generating method for milling of spur gears was proposed. The kinematics model of gear enveloping was established to precisely describe the kinematic relation between the milling tool and workpiece. Based on the accurate model of gear tooth profiles， the scallop point is determined by intersection calculation between the circle of the cutter radius and scallop curve. According to the way that the tool radius is equal to the distance between the scallop point and center point of the cutter arc， the next cutter location(CL) point is identified on the tool path curve. All CL points are determined by the iterative method. On the basis of the CL points on the scallop curve， CL points of the equal radial feeding strategy and equal arc-length feeding strategy were calculated under the constraint of scallop height. The occurrence of global interference was judged by calculating the minimum distance between the milling tool and workpiece. Then the cutting edge angles corresponding to different CL points were given. The occurrence of local over-cut interference was avoided by adjusting the cutter radius. The simulation results showed the proposed method was feasible and effective.

Key words: gear milling; interference-free; constant scallop height; cutter location point; tool path generation

CLC Number:

TH164

WANG Zhen-yu， ZHANG Rong-chuang， YU Tian-biao. Interference-Free Tool Path Generation for Milling of Spur Gears[J]. Journal of Northeastern University(Natural Science), 2022, 43(7): 988-995.

References

[1]Bouquet J，Hensgen L，Klink A，et al.Fast production of gear prototypes—a comparison of technologies［J］.Procedia CIRP，2014，14:77-82.
[2]Klocke F，Brumm M，Staudt J.Quality and surface of gears manufactured by free form milling with standard tools［C］//Proceedings of the International Gear Conference.Lyon:Chandos Publishing，2014:506-515.
[3]Lpenhaus C，Klocke F，Staudt J.Performance of gears manufactured by 5-axis milling［J］.Gear Technology，2017，34(3):58-65.
[4]Yu Y，Lin C，Hu Y.Study on simulation and experiment of non-circular gear surface topography in ball end milling［J］.The International Journal of Advanced Manufacturing Technology，2021，114(7):1913-1923.
[5]zel C.Research of production times and cutting of the spur gears by end mill in CNC milling machine［J］.The International Journal of Advanced Manufacturing Technology，2011，54(1/2/3/4):203-213.
[6]zel C.A study on cutting errors in the tooth profiles of the spur gears manufactured in CNC milling machine［J］.The International Journal of Advanced Manufacturing Technology，2012，59(1/2/3/4):243-251.
[7]Guo E，Ren N，Liu Z，et al.Study on tooth profile error of cylindrical gears manufactured by flexible free-form milling［J］.The International Journal of Advanced Manufacturing Technology，2019，103(9):4443-4451.
[8]郭二廓，任乃飞，任旭东，等.考虑齿面精度特性的渐开线圆柱齿轮包络铣削加工［J］.计算机集成制造系统，2020，26(11):3011-3019.(Guo Er-kuo，Ren Nai-fei，Ren Xu-dong，et al.Free-form milling of involute cylindrical gears considering tooth surface accuracy characteristics［J］.Computer Integrated Manufacturing Systems，2020，26(11):3011-3019.)
[9]Shi Z，Feng Z，Wang P.Study on path planning of involute tooth surface milling with general cutting tool［C］//ASME 2019 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference.Anaheim:American Society of Mechanical Engineers，2019:97156.
[10]Shi Z，Feng Z，Lin S，et al.Milling path planning for helical surface copper electrodes［J］.The International Journal of Advanced Manufacturing Technology，2021，114(3):1031-1048.
[11]Kawasaki K，Tsuji I，Abe Y，et al.Manufacturing method of large-sized spiral bevel gears in cyclo-palloid system using multi-axis control and multi-tasking machine tool［J］.Gear Technology，2011，8:56-61.
[12]lvarez ，Calleja A，Ortega N，et al.Five-axis milling of large spiral bevel gears:toolpath definition，finishing，and shape errors［J］.Metals-Open Access Metallurgy Journal，2018，8(5):8050353.
[13]Spitas V，Costopoulos T，Spitas C.Increasing the strength of standard involute gear teeth with novel circular root fillet design［J］.American Journal of Applied Sciences，2005，2(6):1058-1064.
[14]Zou T，Shaker M，Angeles J，et al.An innovative tooth root profile for spur gears and its effect on service life［J］.Mechanica，2017，52(8):1825-1841.
[15]Feng H Y，Li H.Constant scallop-height tool path generation for three-axis sculptured surface machining［J］.Computer-Aided Design，2002，34(9):647-654.
[16]Luo S，Liao L，Wang J，et al.Study on inspection and avoidance of interferences in five-axis end milling of cycloidal gears［J］.The International Journal of Advanced Manufacturing Technology，2017，91(9):3307-3314.
[13]梅红，王勇.快速收敛的机器人滑模变结构控制［J］.信息与控制，2009，38(5):552-557.(Mei Hong，Wang Yong.Fast convergent sliding mode variable structure control of robot［J］.Information and Control，2009，38(5):552-557.)(上接第971页)
[13]Devadiga H R，Banjab A J，Jallaf M，et al.Reduction in HF emission through improvement in operational practices ［C］//Light Metals.San Antonio:The Minerals，Metals & Materials Society，2013:763-766.
[14]黄安宁，易智民，张利军.420kA大型铝电解槽槽上部集气烟道结构优化改造［J］.有色金属:冶炼部分，2018(5):33-35.(Huang An-ning，Yi Zhi-min，Zhang Li-jun.Optimization and modification of upper flue structure in 420 kA large-scale aluminum reduction cells［J］.Nonferrous Metals:Extractive Metallurgy，2018(5):33-35.)
[15]王瑞金，张凯，王刚.Fluent技术基础与应用实例［M］.北京:清华大学出版社，2007.(Wang Rui-jin，Zhang Kai，Wang Gang.Fluent technology foundation and application examples［M］.Beijing:Tsinghua University Press，2007.)
[16]薛国辉.300 kA铝电解槽高效集气系统的改造和试验［D］.长沙:中南大学，2010.(Xue Guo-hui.Renovation and test of high-efficiency gas gathering system for 300 kA aluminum reduction cell［D］.Changsha:Central South University，2010.)
[17]Zhao R，Gosselin L，Ousegui A，et al.Heat transfer and airflow analysis in the upper part of electrolytic cells based on CFD［J］.Numerical Heat Transfer Part A:Applications，2013，64(4):317-338.
[18]Zhao R，Gosselin L，Fafard M，et al.Heat transfer in upper part of electrolytic cells:thermal circuit and sensitivity analysis［J］.Applied Thermal Engineering，2013，54(1):212-225.
[19]Zhang H，Sun K，Jie L，et al.Numerical simulation study on gas collecting system of 400 kA grade aluminum electrolytic cell［C］//Light Metals.Phoenix:The Minerals，Metals & Materials Society，2018:573-585.
[20]王福军.计算流体动力学分析——CFD软件原理与应用［M］.北京:清华大学出版社，2004.(Wang Fu-jun.Computational fluid dynamics analysis—principle and application of CFD software［M］.Beijing:Tsinghua University Press，2004.)