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Gear is a key component that is relatively difficult to be manufactured compared to many parts. It must be precisely manufactured to the segmentation shape, angle, tooth tip shape, and tooth groove shape of each tooth. Also, because there are many types of gears, it is necessary to rely on the perfect combination of multi-axis machining and special tools enables the precise manufacturing of gears in simultaneous machining.
In the past, gears have always been manufactured by hand. With the popularity of clocks and watches, they began to be mechanized. After the Industrial Revolution, there were particular machines for gears. Although they are collectively called "gears", they have various shapes. Can be divided into spur gears, bevel gears, helical gears, racks, and pinions.
The main methods of gear machining (machining the teeth of the gear) are the gear form/profile grinding method and the Gear generating grinding. The gear form method is a machining method in which a rack-shaped cutting tool is pressed against the disk of the gear, thereby cutting off the circumference of the disk. Compared with the gear form/profile grinding, the gear generating grinding is to use a cutting tool with the same shape as the gear groove to machine material by a milling machine. In addition to the above two methods, there is also the template method to be used to manufacture bevel gears or the plastic forging process.
The machining of gears is extremely complicated. As for the quality, it is difficult to know the tendency of the quality of the gears to change gradually during the processing process by traditional monitoring methods.
If it is high precision machining, the workpiece cannot be unloaded but have to be checked online to avoid the risk of secondary processing. if the quality control inspection is done offline, there may be a high probability that it will be directly scrapped. The best way is to complete the gear processing in one go. In addition, the gears are formed by multi-axis and multi-angle simultaneous machining during the machining process, which means that there are many variables in the measurement required for machining.
With single-finger vibration measurement, there will be many overlaps of timing frequency, coupled with more subtle machining variations, and the constantly changing characteristics of the feed, it is almost impossible to detect errors in the machining process.
Through the wireless transmission characteristics of the smart tool holder, there can be no interference or obstruction in the case of multi-axis simultaneous movement. The bending moment force of the smart tool holder can be used to accurately reproduce the sense of the tool itself during the cutting process of each tooth, weariness, eccentricity during gear forming, multiple impacts between cutter teeth and gears, the uniform force for hobbing to create each mark, and surface roughness monitoring from each tooth tip to each groove, and all immediate responses during machining are presented.
As shown in the figure above, under the cutting force change of each timing characteristic, the force of each tooth is also accompanied by different force trends under the changing feed.
The presentation of such a trend in a polar diagram will expand and contract like concentrically symmetrical flowers. If there is an asymmetric change in one of the teeth, it means that a certain tooth of the workpiece itself has been damaged during the machining process. However, if the cutting force is not uniform in several equal parts, it will be the loss of the blade end, and the blade needs to be replaced immediately.
The model measured by the smart tool holder returns to the essence of gear motion, that is, the signal generated by each tooth and each groove should be equal in force. Coupled with the intuitive polar coordinate diagram, it can be presented simply and clearly. The shaped movement of the gears makes it easier for operators on site to quickly identify quality variations in complex gear processing and improve machining efficiency.
Main image is provided by photographer: Pixabay, link: Pexels
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