Design and analysis of the electronic helical guide controller

ORIGINAL ARTICLE
  • 47 Downloads

Abstract

This paper presents an Electronic Helical Guide Controller (EHGC) for the helical gear shaping process. Considering that the pinion cutter’s reciprocating movement is driven by a crank-connecting rod mechanism in most traditional gear shaping machines, this study adopts this kind of gear shaper as the machine platform to establish an accurate mathematical model. Then, the helical guide movement control algorithm is embedded in the interpolation module of the gear shaping CNC system using the electronic gearbox techniques to realize the special multi-axis linkage control requirements of the helical gear shaping process. The crankshaft’s angular position is measured by the internal sensor, so the rotational speed could be calculated online in each interpolation control cycle. The actual position and the velocity of the shaper cutter along the Z-axis are calculated using the kinematic model of the crank-connecting mechanism, at the same time, the motion of the other axes is controlled by the electronic gearbox. The proposed EHGC is low cost and very easy to implement in practice since it does not need a linear grating ruler and a probe on the Z-axis. The gear machining accuracy can also be estimated online by the EHGC, so as to guide the selection of the process parameters and improve the production efficiency. Experiments are performed to verify the effectiveness of the proposed EHGC.

Keywords

Gear shaping Electronic gearbox (EGB) Generating process Online 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Kim JS, Kang MC, Ryu BJ, Ji YK (1999) Development of an on-line tool-life monitoring system using acoustic emission signals in gear shaping. Int J Mach Tools Manuf 39:1761–1777CrossRefGoogle Scholar
  2. 2.
    Yu B, Zhang LH, Du HQ, Liu FC (2012) Kinematic modeling of the gear shaping based novel cutting area analytical method for large gear shaper. Adv Mater Process Technol 557-559:2225–2228Google Scholar
  3. 3.
    Zhou H, Zhang L, Chen L, Man J, Liu H (2016) Material constitutive modeling of high strain rate and its application in gear shaping cutting force prediction. J Mach Des 33:8–14Google Scholar
  4. 4.
    Tian QH, Tao R, Du YX (2013) Research on three-dimensional topology optimization for the bed of NC gear shaper. Mater Des Process Appl 690-693:2821–2825Google Scholar
  5. 5.
    Tian XQ, Han J, Xia L (2016) A new electronic gearbox for gear hobbing machine. Proc Inst Mech Eng B J Eng Manuf 230(5):923–933CrossRefGoogle Scholar
  6. 6.
    Tian XQ, Han J, Xia L (2015) Precision control and compensation of helical gear hobbing via electronic gearbox cross-coupling controller. Int J Precis Eng Manuf 16(4):797–805CrossRefGoogle Scholar
  7. 7.
    Bouzakis KD, Lili E, Michailidis N, Friderikos O (2008) Manufacturing of cylindrical gears by generating cutting processes: a critical synthesis of analysis methods. CIRP Ann Manuf Technol 57(2):676–696CrossRefGoogle Scholar
  8. 8.
    Wang BM, Mei XS, Wu ZX, Hu CB (2012) Tooth-leap shaping method for helical gears. Adv Mater Process Technol 217-219:1769–1773Google Scholar
  9. 9.
    Fetvaci C, Imrak E (2011) Computer modeling and simulation of spur involute gears by generating method. Adv Des Manuf III 450:103–106Google Scholar
  10. 10.
    Fetvaci C (2010) Generation simulation of involute spur gears machined by pinion-type shaper cutters. Strojniski Vestnik-J Mech Eng 56(10):644–652Google Scholar
  11. 11.
    Fetvaci C (2010) Definition of involute spur gear profiles generated by gear-type shaper cutters. Mech Based Des Struct Mach 38(4):481–492CrossRefGoogle Scholar
  12. 12.
    Han J, Wu LL, Yuan B, Tian XQ, Xia L (2017) A novel gear machining CNC design and experimental research. Int J Adv Manuf Technol 33(5):1711–1722CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2017

Authors and Affiliations

  1. 1.School of Mechanical EngineeringHefei University of TechnologyHefeiPeople’s Republic of China
  2. 2.Department of Mechanical EngineeringUniversity of MichiganAnn ArborUSA

Personalised recommendations