Small modulus spiral bevel gear manufacturers: introduction of small modulus spiral bevel gear dry cutting status

For a long time, the gear machining process of small modulus spiral bevel gear mainly adopts the oil injection method of "wet cutting. Due to historical reasons, a large number of domestic gear manufacturers still use mechanical or semi-numerical control machine tools to process arc contraction spiral bevel gears according to the "five-knife method" (Gleason fixed installation method). The design and manufacture of small modulus spiral bevel gears generally adopt arc contraction tooth system, and the cutting teeth are designed and calculated according to the "double (composite) double-sided method. The general generation method without tool tilt is only applicable to large and small wheels.

Most of the processing equipment is a simple milling machine with B- axis structure, without a tool tilt mechanism. The adjustment of contact area mainly depends on artificial experience, and there is no uniform accuracy evaluation standard for tooth surface quality, which belongs to a wide range of backward processing and manufacturing modes.

On the other hand, with the development and progress of machine tools, tools, materials and technology, the "dry cutting" technology of spiral bevel gears with high efficiency, high precision, energy saving and environmental protection, and low cost has become a reality, which has attracted the attention of many gear manufacturers., And gradually applied to the tooth profile cutting of cycloid and other high-tooth bevel gears. There are few reports on the application of dry cutting of small modulus spiral bevel gear in China. At present, it mainly stays in the experimental stage, limited to the arc contraction gear system. Single-disk cutting tool processing is small, high cost, difficult to promote the application. The main reason for the difficulty in the application of small module dry cutting is the high price of foreign small-size processing equipment; secondly, the domestic small module product processing entry threshold is low, and the quality requirements are not high.

A wide range of low-end manufacturing and vicious competition lead to low profit margins, further affecting the application of small module dry cutting equipment; Third, the commonly used simple machine tool structure, stiffness, spindle speed and related configuration can not meet the requirements of dry cutting; Sharp cutter and sharp tooth blade grinding and assembly is also a bottleneck restricting the application of dry cutting technology.

The advantages of small modulus spiral bevel gear dry cutting:

Compared with the traditional "wet cutting" process, dry cutting has many advantages, high processing efficiency, production efficiency increased by at least 6 times; dry cutting accuracy can be improved by at least 2 levels, reaching more than din5; tooth surface roughness can reach or exceed 1.6 microns, almost equivalent to grinding teeth; long service life of sharp teeth. After a grinding and coating, the workpiece can be processed more than 6-10 times; more importantly, the machine tool does not require oil cooling, and the waste oil treatment fee, cutting oil fee, oil mist separator, cutting oil circulation filter system power consumption and other related costs can be ignored, further reducing production costs and realizing green manufacturing. These advantages will become the future development trend of spiral bevel gear machining.

There are two processing methods for small modulus spiral bevel gears. One is the forming method, that is, the method of using a forming milling cutter to cut the tooth profile. The forming milling cutter is completely consistent with the shape of the tooth slot to be cut, such as milling teeth; the other is the expansion method, which uses the gear cutter and the driven gear The meshing between the gears and the movement to cut the tooth profile, such as hobbing and tooth shaping.