Yancheng XINLAN Precision Machinery Co., Ltd.

To adaptGear processingThe industry's requirements for manufacturing precision, production efficiency, cleaner production, and improved quality have led to the following development trends in gear-making machine tools and gear-making technology. 

1. Numerical control 

After CNC control of each motion axis of the machine tool and linkage between some of the axes, it has the following advantages:

(1) The functions of the machine tool are increased, such as hobbing of small tapers and drum gears, etc., becomes extremely simple.

(2) After shortening the transmission chain, and adopting semi-closed loop or full closed loop control, the positioning accuracy and repeat positioning accuracy of each axis can be improved through numerical control compensation, thereby improving the machining accuracy and Cp value of the machine tool, and increasing the reliability of the machine tool .

(3) The time required for calculation and change of gear change gears and differential change gears, feed and spindle gear shifts is omitted when changing varieties, and the gear shaper also eliminates the time for changing inclined guide rails, thereby reducing auxiliary processing. Time increases the flexibility of the machine tool.

(4) As the mechanical structure becomes simple, it can be designed to be more conducive to improving the rigidity of the machine tool and reducing the thermal deformation to the bottom.

(5) There is no mechanical connection between the shafts, and the structural design becomes typical, which is more conducive to the implementation of modular design and manufacturing.

2. High speed and high efficiency 

The high speed of gear processing machine tools such as gear hobbing machines, gear shapers and gear grinding machines mainly means that the machine tools have high tool spindle speed and high table speed, which are the main indicators to improve cutting efficiency. 

Efficient processing is ensured by the machine tool adopting special technologies from all aspects: the casting bed with the best vibration absorption effect; the integrated cooling medium circulation system that makes the machine tool have the best thermal stability; the large inclination angle and smooth design of the protective partition in the cutting zone The chips produced by dry cutting can be discharged quickly and effectively; it has a feed system driven by a preloaded, gapless ball screw; it has a wear-resistant linear guide or a quantitatively lubricated cast iron guide with PLC control.The application of the electric spindle increases the tool spindle, and the increase of the table speed is the use of a high-precision helical gear pair or a torque motor.The electric spindle and torque motor have the advantages of high rotation accuracy, no backlash and no maintenance. 

3. High precision 

由于采用了高精度、具有预加负荷的高刚性直线导轨、滚珠丝杆、滚动轴承、电主轴、力矩电动机及数控技术，使高速加工条件下的齿轮加工机床精度得到保证并有所提高。电主轴精度一般为径向振摆0.002mm,轴向0.001mm;环形转矩伺服电动机定位精度达0.5″，重复定位精度达0.01″；直线运动轴的定位精度小于0.008mm,重复定位精度小于0.005mm.滚齿及插齿尽管为粗加工，但在高速切削的条件下仍能达到DIN6~7级精度，为其后的精加工工序获得高精度提供了保证。

4. Functional composite 

The functional compound machine tool means that it can complete multiple processes on a machine tool or in one clamping of the workpiece, thereby improving the processing efficiency and even accuracy of the workpiece.

5. Green and environmental protection 

The application of cutting fluid in the cutting process can increase the life of the tool, improve the quality of the machined surface and help to discharge the cutting heat without causing thermal deformation of the machine tool.However, the splash of cutting fluid and the oil mist formed during high-speed cutting are particularly harmful to the ecological environment, especially the health of the operator.For this reason, the processing area is usually enclosed with a protective cover, and an oil mist separator is installed, so that only oil-free mist is discharged, and the cutting oil is returned to the machine tool for recycling.But this does not fundamentally solve the environmental problem, because the replacement and discharge of deteriorated cutting fluid will seriously pollute the environment. 

The cost of cutting fluid and cutting fluid additional devices consumed in wet gear machining account for about 20% of the machining cost. The use of high-speed dry cutting can increase the machining efficiency by more than 2 to 3 times. The service life of the tool is 2 to 5 of that of wet cutting. Therefore, dry cutting reduces the machining cost of a single piece of gear. 

High-speed dry cutting can not only reduce the consumption of cutting fluid and cooling processing equipment, but also avoid environmental pollution, increase production efficiency, and reduce the manufacturing cost of a single gear.Therefore, high-speed dry cutting has become the goal and development direction pursued by gear machining machine tool manufacturers for many years.With the high speed of gear processing machine tools, the improvement of machine rigidity, the improvement of good vibration resistance and chip removal technology, and the further development of dry high-speed cutting tools, high-speed dry cutting has been fully realized on gear cutting machine tools. 

6. Intelligent 

The combination of digital control technology, sensor technology, information technology and network control technology makes CNC gear processing machine tools more intelligent. 

 Gear processing machine tools need to realize error compensation, temperature compensation, automatic balance, anti-collision function, overload protection, automatic identification of whether there is a workpiece, whether the workpiece is clamped correctly, whether the workpiece has been processed, tooth meshing, machining allowance distribution, tool wear , On-line precision inspection, automatic dressing of the grinding wheel, zero programming interface, multi-function processing software, cutting process expert system, automatic identification, remote control, remote diagnosis and other functions when robots move workpieces between machine tools. 

Intelligentization is the basis for gear machine tools to improve reliability, safety, stability, complex parts processing, precision processing, and realization of unmanned production, and it will continue to be improved and improved. 

Gear processing is developing in the direction of high efficiency, high precision and green manufacturing, and gear processing machine tools are developing in the direction of full numerical control, functional compound, intelligence, automation and information.Chinese gear processing machine tool manufacturers should seize this development trend and better provide my country's automotive gear processing industry with efficient, complex and intelligent equipment.