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A pitch deviation compensation technology for precision manufacturing of small modulus copper electrode gears

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Abstract

The machining accuracy of a copper electrode gear (CEG), especially the pitch deviation of CEG, is affected by the wear of the ball end mill (BEM) with the increase of the length of milling path. Based on the error mapping principle, this work focuses on the influence of BEM wear on pitch deviation. In order to dynamically compensate the influence of the BEM wear on pitch deviation, a novel milling pitch deviation compensation model was proposed based on the formation mechanism and measurement principle of pitch deviation. To ensure the uniform wear at the milling edge of the BEM during the milling process, BEM wear was firstly copied to the pitch deviation according to the tooth-by-tooth milling strategy. Then, the BEM wear curve was fitted based on orthogonal experiments and multiple linear regression. According to the wear curve, an offline compensation method was adopted to compensate for the pitch deviation caused by BEM wear. In addition, the reverse compensation principle was used to compensate for the normal deviation of BEM milling path. Finally, the compensation model was verified by milling experiments. Pitch deviation met the requirements of Levels 4\(\sim \)5 in GB/T 38192-2019. The model can be used to guide the milling process of CEG.

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Acknowledgements

The authors would like to thank Zhongshan Mltor CNC Technology Co., Ltd., and Dongguan Xinghuo Gear Co.,Ltd for their active support in the preparation of this paper.

Funding

This document is supported by the State Key Program of National Natural Science Foundation of China (grant no. 51635001) and the results of the research project funded by National Natural Science Foundation of China (Grant No. 51775003).

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Authors and Affiliations

  1. Beijing Engineering Research Center of Precision Measurement Technology and Instruments, Beijing University of Technology, No.100, Pingleyuan, Chaoyang District, 100124, Beijing, China

    Zhipeng Feng, Zhaoyao Shi & Peng Wang

  2. Dongguan Xinghuo Gear Co., Ltd., No. 19, Baoshi Road, Tangxia Town, 523715, Dongguan City, Guangdong Province, China

    Aijun Tong

  3. Zhongshan Mltor CNC Technology Co., Ltd., No. 43, Keji West Rd, Torch Development Zone, 528437, Zhongshan City, Guangdong Province, China

    Shoujin Lin

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  1. Zhipeng Feng
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  2. Zhaoyao Shi
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Contributions

Zhipeng Feng: Roles/Writing - original draft. Zhaoyao Shi: Conceptualization of this study, Methodology. Aijun Tong and Shoujin Lin: Provide experimental equipment and technical guidance. Peng Wang: Writing - review and editing.

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Correspondence to Zhaoyao Shi.

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Feng, Z., Shi, Z., Tong, A. et al. A pitch deviation compensation technology for precision manufacturing of small modulus copper electrode gears. Int J Adv Manuf Technol 118, 1511–1527 (2022). https://doi.org/10.1007/s00170-021-07966-8

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  • DOI: https://doi.org/10.1007/s00170-021-07966-8

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