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Research Papers

Synthesis of Shaped Noncircular Gear Using a Three-Linkage Computer Numerical Control Shaping Machine

[+] Author and Article Information
Fangyan Zheng, Lin Hua

School of Automotive Engineering,
Hubei Key Laboratory of Advanced Technology
of Automotive Parts,
Wuhan University of Technology,
Wuhan 430070, China

Xinghui Han

School of Automotive Engineering,
Hubei Key Laboratory of Advanced Technology
of Automotive Parts,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: hanxinghuihlp@126.com

Bo Li, Dingfang Chen

School of Logistics Engineering,
Wuhan University of Technology,
Wuhan 430063, China

1Corresponding author.

Manuscript received June 30, 2016; final manuscript received January 9, 2017; published online March 8, 2017. Assoc. Editor: Laine Mears.

J. Manuf. Sci. Eng 139(7), 071003 (Mar 08, 2017) (12 pages) Paper No: MANU-16-1357; doi: 10.1115/1.4035794 History: Received June 30, 2016; Revised January 09, 2017

Gear shaping, commonly regarded as the most widely used machining method for cylindrical gear, is in fact an ideal manufacturing method for noncircular gear due to its merit of not being restricted by gear type or pitch curve in contrast to gear hobbing. However, concerning researches are mainly focused on the generation of noncircular straight external gear, paying rare attention to noncircular internal gear and noncircular helix gear. Considering that this paper, through using a three-linkage computer numerical control (CNC) shaping machine, aims to synthesize shaped noncircular gear, covering external, internal, straight, and helix gear. The mathematical model, a three-linkage model, is first established. The corresponding manufacturing process in practice is subsequently discussed. Finally, with practical shaping experiments, the correctness of the proposed model and the appropriateness of the manufacturing process are verified.

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Figures

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Fig. 1

Section of helix shaper cutter

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Fig. 2

Tooth surface formation of helix shaper cutter

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Fig. 3

Tooth surface of involute helix-gear shaper cutter

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Fig. 4

Coordinate systems of tooth profile generation for noncircular external (a) and internal gears (b)

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Fig. 5

Example of the generated noncircular helix external gear drive

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Fig. 6

Example of the generated noncircular helix internal gear drive

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Fig. 7

The configurations of three-linkage helix gear shaping machine

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Fig. 8

Coordinate systems for three-linkage helix gear shaping machine

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Fig. 9

Illustrations of shaping noncircular external (a) and internal gears (b)

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Fig. 10

Illustrations of shaped gear in cycle 1 (a), cycle 2 (b), and cycle 3 (c)

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Fig. 11

(Angular) velocity of A-axis (a), B-axis (b), and X-axis (c) in different interpolation methods

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Fig. 12

(Angular) acceleration of A-axis (a), B-axis (b), and X-axis (c) in different interpolation methods

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Fig. 13

Rate of cutting arc length in each cutting step in different interpolation methods

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Fig. 14

Interpolation errors

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Fig. 15

Max interpolation errors of A-axis (a), B-axis (b), and X-axis (c) in different interpolation methods

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Fig. 16

Blank design for external (a) and internal (b) shaped gear

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Fig. 17

Interference area in the process of shaping noncircular gear

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Fig. 18

Process of shaping noncircular external straight gear

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Fig. 19

Process of shaping noncircular internal straight gear

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Fig. 20

Process of shaping noncircular external helix gear

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Fig. 21

Finished noncircular external straight gear

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Fig. 22

Finished noncircular internal straight gear

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Fig. 23

Finished noncircular external helix gear

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