The article primarily discusses the issue of low machining precision in CNC heavy-duty gear shaving due to the coupling of various errors from the gear shaving machine. It proposes an error compensation method to address this problem. Based on a mathematical model derived from the principle of spatial staggered-axis helical gear meshing. The method’s feasibility is validated through a calculation example of an internal cylindrical gear shaving process. Below is a summary of the key points from the article:
1. Analysis of Error Sources
1. Analysis of Error SourcesIn CNC heavy-duty gear shaving, errors in the machine tool (including geometric errors, dynamic errors, and errors caused by cutting forces during machining) lead to inaccuracies in the tooth profile. These errors are particularly significant in the machining of internal cylindrical gears. Where they have a more pronounced effect on the tooth profile. The coupling of these errors causes a decrease in machining precision.
2. Mathematical Modeling
The article establishes a mathematical model for the CNC heavy-duty gear shaving process of internal cylindrical gears based on the principle of spatial staggered-axis helical gear meshing. By comparing the tooth surface equation with errors and the theoretical tooth surface equation, the impact of machine tool adjustment errors on the tooth profile deviation is analyzed.
3. Analysis of Error Patterns
By comparing the deviations caused by errors in the tooth surface with the theoretical tooth surface, the article reveals the variation patterns of machine tool adjustment errors (such as positioning errors, tool errors, and workpiece installation errors) and their effects on the normal deviation of the tooth profile. These patterns provide a theoretical basis for further error compensation.
4. Error Compensation Method
A new error compensation method based on a tooth profile error sensitivity coefficient matrix is proposed. Specifically, the correlation function between machine tool adjustment parameter errors and tooth profile deviations is established. By analyzing the sensitivity of each adjustment parameter to the tooth profile, targeted error compensation is performed. This compensation method can effectively correct the tooth profile deviations caused by machine tool errors.
5. Computational Example Validation
The article validates the proposed error compensation method through a computational example of the CNC heavy-duty shaving process of an internal cylindrical gear. In addition, the results show that the tooth profile deviations caused by machine tool adjustment parameter errors were significantly corrected, and the machining precision was effectively improved.
6. Research Results and Significance
The research demonstrates that the proposed error compensation method based on a sensitivity coefficient matrix for tooth profile errors can significantly improve the precision of CNC heavy-duty gear shaving, especially in cases where machine tool adjustment errors are present. This method corrects tooth profile deviations and achieves the desired machining precision. It has important engineering applications for improving the quality and efficiency of internal cylindrical gear machining.