JP4182137B1 - Gear machining method - Google Patents

Abstract

An object of the present invention is to chamfer an end face corner portion of a tooth surface of a gear to be cut and to suppress a bulge in the vicinity of the end face corner portion.
In step S101, gear cutting with a hob or the like is performed on a material. In step S102, the work gear 14 is chamfered. In step S103, carburizing and quenching by heat treatment of the work gear 14 is performed. In step S104, gear grinding of the work gear 14 is performed. In step S105, gear honing of the work gear 14 is performed. In step S102, the end face corner portions 30 and 31 of the work gear 14 are chamfered by rotating the phrasing cutter 18 with the work gear 14 having a non-zero axis crossing angle ψ.
[Selection] Figure 22

Description

  The present invention relates to a gear machining method for appropriately chamfering a corner portion of an end face of a gear.

  Modern automobiles are required to be quiet and durable while having high output, and the gears used for power transmission (for example, transmissions) are more powerful so that power is reliably transmitted and noise is not generated. An accurate tooth surface is desired.

  Such high-precision gear machining is generally performed by rough cutting with a hob, chamfering, tooth surface shaping with a shaving cutter, carburizing and quenching by heat treatment, and gear grinding or chamfering to further improve accuracy. Gear honing is performed.

  Among these, at the stage where the rough cutting with the hob is completed, the end face corner of the tooth surface is sharp, and as it is, there is a concern that excessive carburization is performed by heat treatment, and the glass is hardened (weakened). For this reason, chamfering is performed to prevent excessive carburization and to improve the gear strength.

  As chamfering, a phrasing cutter that crushes the end face corners of the tooth surface of the gear to be cut is widely used. The phrasing cutter meshes with the work gear without crossing the shaft and crushes the corners of the gear. Examples of a processing method using a phrasing cutter include Patent Document 1 and Patent Document 2. Patent Document 1 discloses that a phrasing cutter meshes with a work gear with an axis crossing angle of 0 °. Patent Document 2 discloses that a phrasing cutter is engaged with a work gear with a predetermined axis crossing angle.

  Patent Document 3 discloses a gear machining device that continuously performs gear cutting and end face processing in one device.

JP-A-54-15596 JP-A-61-284318 JP 2006-224228 A

  As described above, high-precision gears that require high output, quietness, and durability generally require rough cutting, chamfering with a phrasing cutter, tooth surface formation with a shaving cutter, heat treatment, and gear grinding. Gear honing is performed.

  In chamfering with a phrasing cutter, the end face corners of the tooth surface can be properly chamfered, but basically the crushing process results in the surplus being pushed out to the side, and the rise due to the surplus Occurs.

  Such a raised part can be removed by grinding in a subsequent grinding process, but heat treatment is performed before the grinding process, and the raised part is considerably harder. The applied load is large and the grinding takes time. In addition, it is desirable that the grinding process is costly from the viewpoint of production efficiency and can be omitted.

  If the grinding process is omitted, the load on the grindstone is extremely large in the subsequent gear honing process, which is not preferable. After the heat treatment, the hardness of the machined gear is high, and the gear honing wheel and the machined gear are in contact with each other during machining, and only the part that contacts the raised part is extremely worn. It is.

  In the tool described in Patent Document 2, the phrasing cutter is meshed with the work gear with a predetermined crossing angle. However, if the crossing angle is inadvertently provided, the end of the teeth of the phrasing cutter is covered. It interferes with the tooth surface of the cutting gear. Moreover, this tool is provided with serrations as cutting blades on the tooth surface, and is difficult to manufacture.

  In addition, the shaving process performed after the chamfering process also has an effect of suppressing the swell, but it takes a considerable amount of time than the chamfering process, and the so-called tact time becomes longer. There may be a waste of waiting time before doing so.

  On the other hand, even for gears that require relatively low accuracy and are not heat-treated, if the tooth surface finish such as shaving is performed without taking measures against the raised portion generated by chamfering of the phrasing cutter, the raised portion will be applied to the tool. The tool life is inevitably shortened due to the load. As a result, the number of times that the machine tool is stopped for the tool change operation, the number of times of maintenance and inspection increases, and there is a concern about an increase in tool costs.

  The present invention has been made in consideration of such problems, and provides a gear machining method for appropriately chamfering the end face corner of the tooth surface and suppressing the occurrence of bulge in the vicinity of the end face corner. Objective.

  The gear machining method according to the present invention has the following characteristics.

  First feature: A chamfering step of chamfering a corner of an end face of the work gear by rotating the phrasing cutter meshed with the work gear with an axis crossing angle ψ, and a toothing after the chamfering step. It has the heat processing process which heats the said to-be-cut gear without surface shaping, and one or more tooth surface finishing processes which shape | mold the tooth surface of the said to-be-cut gear after the said heat treatment process.

  In this way, since the phrasing cutter meshes with the work gear with an axis crossing angle ψ, not only chamfering is performed by crushing the end face corner of the work gear, but also the surging of the surplus due to the crushing occurs. Can be suppressed. Further, if the heat treatment process is performed after the chamfering process without forming the tooth surface, the number of processes is reduced, which is efficient.

  Second feature: If the tooth surface of the phrasing cutter is an involute surface having no corners as a cutting blade, the phrasing cutter can be easily manufactured.

  Third feature: For the tooth surface finishing process, for example, any one or more of a finishing hob process, a gear grinding process, a honing process, and a reamer process can be selected.

  Fourth feature: a workpiece support portion that pivotally supports the workpiece gear, and a cutter support portion that pivotally supports the phrasing cutter so as to mesh with the workpiece gear provided on the workpiece support portion. The cutter support section may mesh the phrasing cutter with the work gear with an axis crossing angle ψ.

  Fifth feature: the work support part is provided on a turntable that adjusts the orientation with respect to the cutter support part. An appropriate axis crossing angle ψ according to the work gear can be set by the turntable.

  Sixth feature: A helical gear is applicable as the work gear.

  Seventh feature: The work gear may be a gear of a vehicle transmission. A gear machined by the gear machining method of the present invention has high accuracy, is excellent in quietness and durability, and is suitable for a vehicle transmission.

  Eighth feature: a chamfering process for chamfering the corner of the end face of the work gear by rotating the phrasing cutter meshed with the work gear with an axis crossing angle ψ, and a heat treatment after the chamfering process. 1 or more 1st tooth surface finishing process which shape | molds the tooth surface of the said to-be-cut gear without carrying out, It is characterized by the above-mentioned.

  In this way, since the phrasing cutter meshes with the work gear with an axis crossing angle ψ, not only chamfering is performed by crushing the end face corner of the work gear, but also the surging of the surplus due to the crushing occurs. Can be suppressed.

  Further, the present invention can be applied to a gear whose required accuracy is not relatively high without performing a heat treatment step. In the stage of the first tooth surface finishing process performed after the chamfering process, since the raised portion is hardly generated, the load on the tool used in the first tooth surface finishing process is small, and the tool life can be extended. Thereby, while reducing the frequency | count of stopping a machine tool for a tool change operation | work, the frequency | count of a maintenance and inspection, tool expense can be suppressed.

  Since the heat treatment is not performed at the stage of the first tooth surface finishing process, it is easy to process the work gear.

  Ninth feature: Preferably, the first tooth surface finishing step is a shaving step.

  Tenth feature: A heat treatment step of heating the work gear may be provided after the first tooth surface finishing step. The heat treatment step increases the hardness of the work gear, and is suitable, for example, for a highly accurate vehicle transmission gear that requires high output, quietness, and durability.

  Eleventh feature: one or more second tooth surface finishing steps for forming a tooth surface of the work gear after the heat treatment step. By performing the tooth surface finishing process separately before and after the heat treatment, high-accuracy machining is possible. The second tooth surface finishing step increases the accuracy of the work gear, and is more suitable, for example, for a highly accurate vehicle transmission gear that requires high output, quietness, and durability.

  Twelfth feature: For the second tooth surface finishing process, for example, any one or more of a finishing hob process, a gear grinding process, a honing process, and a reamer process can be selected.

  Thirteenth feature: Gear processing including a workpiece support portion that pivotally supports the workpiece gear, and a first step portion and a second step portion that sequentially move by moving relative to the workpiece support portion. Using the apparatus, the chamfering step is performed in the first process unit, and the first tooth surface finishing process is performed in the second process unit.

  14th characteristic: The said gear processing apparatus has a 3rd process part which moves relatively with respect to the said workpiece | work support part, and processes the said to-be-cut gear after the process in a said 2nd process part. The third process unit includes a shaving cutter that processes a tooth surface of the work gear, and the work support unit is at least according to the first process unit, the second process unit, and the third process unit. Three units are provided, and the three work gears are processed simultaneously by the first process unit, the second process unit, and the third process unit.

  In general, the shaving process takes more time than the chamfering process by the phrasing cutter, but by performing the shaving process separately in the second process part and the third process part, the time difference between the first process of the chamfering process can be reduced. And a useless waiting time after the first step can be reduced.

  15th characteristic: The said 1st process part and the said 2nd process part are provided in a turret mechanism, move to the position which faces the said work support part in order by rotation of this turret mechanism, and process the said to-be-cut gear. It is characterized by. By using the turret mechanism, it is possible to perform chamfering with a phrasing cutter and processing of a tooth surface with a shaving cutter in one gear machining apparatus, which is efficient.

  Sixteenth feature: The rotation axis of the turret mechanism has an axis crossing angle ψ with respect to the axis of the workpiece support portion. That is, since both the phrasing cutter and the shaving cutter are engaged with the work gear with an axis crossing angle, the turret mechanism itself can be set obliquely, resulting in a simple configuration.

  17th characteristic: 3rd process part which is provided separately from the said turret mechanism, moves relatively with respect to the said workpiece | work support part, and processes the said work gear after the process in a said 2nd process part. The third process unit includes a shaving cutter that processes a tooth surface of the work gear, and the work support unit is provided in at least two units according to the turret mechanism and the third process unit, The two work gears are processed simultaneously by the turret mechanism and the third process section.

  In general, the shaving process takes more time than the chamfering process by the phrasing cutter, but the shaving process is performed by dividing the shaving process into the second process part of the turret mechanism and the third process part other than the turret mechanism. The time difference can be reduced, and the useless waiting time after the first step can be reduced.

  18th characteristic: It has a 3rd process part which moves relatively with respect to the said work support part, and processes the said to-be-cut gear after the process in a said 2nd process part, The said 3rd process part Comprises a shaving cutter for machining the tooth surface of the work gear, and the phrasing cutter of the first process part, the shaving cutter of the second process part and the shaving cutter of the third process part are respectively connected to the turret mechanism. It is provided.

  By using the turret mechanism, it is possible to perform chamfering with a phrasing cutter and processing of a tooth surface with a shaving cutter in one gear machining apparatus, which is efficient. In addition, since the shaving process is performed separately for the second process part and the third process part, it is possible to properly use appropriate tools with the second process part as a rough finish and the third process part as a fine finish.

  According to the gear machining method of the present invention, since the phrasing cutter meshes with the work gear with an axis crossing angle ψ, not only chamfering is performed on the end face corner of the work gear but also crushing is performed. It is possible to suppress the occurrence of surging of surplus meat.

  Further, if the heat treatment step is performed after the chamfering step without forming the tooth surface, the number of steps is reduced, which is efficient.

  Furthermore, by performing the tooth surface finishing process separately before and after the heat treatment, high-accuracy processing is possible.

  Embodiments of the gear machining method according to the present invention will be described below with reference to FIGS. In the gear machining method according to the present embodiment, at least chamfering is performed on the end face corner of the gear to be cut after the coarse gear cutting process using the hob. The gear machining method according to the present embodiment is performed using, for example, a gear machining apparatus 10a (see FIG. 19), 10b (see FIG. 20), and 10c (see FIG. 21). Regarding these gear machining apparatuses 10a to 10c, first, the machining unit 12 for machining a work gear with a phrasing cutter will be described.

  As shown in FIG. 1, the machining section 12 includes a shaft J1 as a work support section that pivotally supports the work gear 14, a phrasing cutter 18, and an axis J2 as a cutter support section that pivotally supports the phrasing cutter 18. Have The axis J2 can be rotated by a drive source (not shown). The axis J <b> 1 is rotated when the work gear 14 meshes with the phrasing cutter 18.

  The shaft J2 pivotally supports the phrasing cutter 18 so as to mesh the phrasing cutter 18 with the work gear 14 provided on the shaft J1. The axis J2 meshes the phrasing cutter 18 with the work gear 14 with a non-zero axis crossing angle ψ, and the machining teeth 32a and 32b of the phrasing cutter 18 do not interfere with the tooth surface 28 of the tooth 26 of the work gear 14 It is provided at an angle (see FIG. 5). The axis crossing angle ψ is an angle formed by the axis J1 of the work gear 14 and the axis J2 of the phrasing cutter 18 (see FIG. 5).

  As shown in FIG. 2, the work gear 14 is, for example, a helical gear, and in a state of rough cutting, there are sharp portions 33 (see FIG. 7A) at the left and right end face corner portions 30 and 31. The sharpened portion 33 is chamfered at the processing portion 12. The work gear 14 to be processed by the processing unit 12 is not limited to a helical gear, and may be a spur gear or the like. The work gear 14 is, for example, a gear of a vehicle transmission. The gear processed by the processing unit 12 has high accuracy, is excellent in quietness and durability, and is suitable for a vehicle transmission.

  As shown in FIG. 3, the phrasing cutter 18 is provided with a first piece 34a including a group of chamfering processing teeth 32a on one side in the thickness direction, and a second piece 34b including a group of chamfering processing teeth 32b on the other side. Is provided. The 1st piece 34a and the 2nd piece 34b are structures fixed with respect to the boss | hub 36, and are what is called a three piece type. The first piece 34 a and the second piece 34 b can each be adjusted in angle with respect to the boss 36 by using the arc hole 38.

  As shown in FIGS. 4 and 5, the machining teeth 32 a and the machining teeth 32 b are separated according to the thickness of the work gear 14, and the phrasing cutter 18 and the work gear 14 rotate while meshing, and the phrasing cutter is obtained. The processing teeth 32a of the portion 40a press against the end face corner portion 30 to crush the sharp portion 33 and chamfer it. The processing teeth 32b of the phrasing cutter part 40b press against the other end face corner part 31 to crush the sharp part 33 and chamfer it.

  FIG. 5 shows a relative positional relationship between the teeth 26 of the work gear 14 and the machining teeth 32a and 32b of the phrasing cutter 18, and each of the work gear 14 and the phrasing cutter 18 is disposed along the circumferential surface. It is the expanded schematic diagram. As is clear from FIG. 5, the work gear 14 and the phrasing cutter 18 have an axis crossing angle ψ and intersect each other at an angle.

  On the other hand, as shown in FIG. 6, there is no axis crossing angle ψ in the meshing according to the prior art.

  Next, the effect | action which the process tooth 32a of the phrasing cutter 18 presses with respect to the end surface corner | angular part 31 and crushes the sharp part 33 is demonstrated.

  The work gear 14 rotates in the right direction in FIG. 5, that is, in the direction of the arrow A1, and the phrasing cutter 18 rotates in the oblique direction, that is, in the direction of the arrow A2 by an angle ψ.

  As shown in FIG. 7A, the processing tooth 32 a of the phrasing cutter 18 first comes into contact with a substantially top portion P <b> 1 of the end face corner portion 30 of the tooth 26. At the initial stage of meshing at this time, the processing teeth 32a are inclined diagonally to the right with respect to the teeth 26, and the front side of the center line C is in contact with the portion P1. At this time, a sharp portion 33 exists in the end face corner portion 30. 7A to 7C, a center line C is added to the tooth surface of the processing tooth 32a for easy understanding. The meshing at this time corresponds to the meshing shown by the arrow B1 in FIG.

  As shown in FIG. 7B, in the middle stage of the meshing, the processing teeth 32a of the phrasing cutter 18 are in contact with a point P2 at a substantially intermediate height of the teeth 26. In the middle stage of meshing, the processing teeth 32a are substantially parallel to the teeth 26, and the center line C abuts on the location P2. At this time, the upper portion of the portion P2 is chamfered and the sharp portion 33 is chamfered, but the sharp portion 33 remains below the portion P2. The meshing at this time corresponds to the meshing shown by arrow B2 in FIG.

  As shown in FIG. 7C, at the end of the meshing, the processing teeth 32 a of the phrasing cutter 18 abut on a position P <b> 3 at a substantially bottom portion of the teeth 26. At the end of meshing, the processing teeth 32a are inclined obliquely to the left with respect to the teeth 26, and the back of the center line C abuts on the place P3. At this time, the end face corner part 30 is chamfered over the entire length, and the sharp part 33 disappears. The meshing at this point corresponds to the meshing shown by arrow B3 in FIG.

  As shown in FIG. 8, the end face corner portion 30 that has been chamfered has an elongated flat surface portion, and the sharp portion 33 is eliminated. Here, as shown by the arrow D1, the locus of movement of the processing tooth 32a is an oblique direction and includes a lateral movement component.

  9A and 9B show the movement trajectory of the tooth surface of the phrasing cutter at the end face corner 30 in more detail. FIG. 9A shows a case where the axis crossing angle ψ is 5 °, and FIG. 9B shows a case where the axis crossing angle ψ is 8 °. Reference symbol Z indicates a meshing circle between the work gear 14 and the phrasing cutter 18. As can be understood from FIGS. 9A and 9B, the movement trajectory includes a considerable amount of the lateral component, and this component is larger when the axis crossing angle ψ is 8 ° than when it is 5 °. The larger the transverse component, the better the normal machinability.

  On the other hand, in the meshing according to the prior art (see FIG. 6), there is no axis crossing angle ψ (that is, ψ = 0), so the locus of movement of the machining teeth 32a is indicated by an arrow E in FIG. As shown, the lateral movement component is not included.

  That is, according to the machining section 12 of the gear machining apparatus, the phrasing cutter 18 meshes with the work gear 14 with an axis crossing angle ψ, so that the end face corner 30 of the work gear 14 is crushed and sharpened 33. In addition to chamfering, sliding between surfaces including a lateral movement component occurs. Thereby, generation | occurrence | production of the surplus swell in the location 82 (refer FIG.8 and FIG.10) adjacent to a chamfering part among the tooth surfaces 28 can be prevented, or it can suppress.

  The tooth surfaces of the processing teeth 32 a of the phrasing cutter 18 are intended to be pressed and slid with respect to the end face corner portions 30. Therefore, the tooth surface of the phrasing cutter 18 is an involute surface having no corners and is easy to manufacture.

  In addition, although detailed description is abbreviate | omitted, also about the end surface corner | angular part 31 of the opposite side in the to-be-cut gear 14, the sharp point 33 is appropriately chamfered by the process tooth 32b of the phrasing cutter 18, and the location adjacent to a chamfering part Generation | occurrence | production of the surplus swell in 82 (refer FIG. 10) can be prevented or suppressed. In this case, as shown by the arrow D2 in FIG. 10, the locus of movement of the processing teeth 32b is an oblique direction and includes a lateral movement component, and the same effect as the processing on the end face corner portion 30 is obtained. It is done. The details of the trajectory of this movement are the opposite directions of the arrows in the case shown in FIGS. 9A and 9B.

  By the way, in the meshing according to the prior art, the axis crossing angle ψ generally does not exist (see FIG. 6). The reason for this is that it is not possible to overlook the surging of the surplus that occurs at the location 82 (see FIG. 8) adjacent to the chamfered portion, or to provide an effective axis crossing angle ψ as a solution. It depends.

  In the device described in Patent Document 2, an axis crossing angle ψ is provided, but it is actually not easy to chamfer the end face corners 30 and 31 by serration.

  Further, the provision of the axis crossing angle ψ may cause the processing teeth 32a and 32b of the phrasing cutter 18 to interfere with the tooth surface 28 of the tooth 26 of the work gear 14 (see the phantom line in FIG. 6). The difficulty is also considered to be a factor.

  As an appropriate setting of the axis crossing angle ψ, the following equation (1) is appropriate.

  Here, the upper left side is the amount of interference with the phrasing cutter 18 of the work gear 14, and interference can be avoided if the processing teeth 32 a and 32 b are set thin by the value indicated by the upper left side. The right side shows the cosine component of the tip width of the processed teeth 32a and 32b.

Further, in the equation (1), as shown in FIG. 11, l ₁ is a chamfer width, l ₂ is a lapping amount, BOG is a gear deflection angle, and SBG is a meshing circular arc tooth thickness. DBG is a gear meshing swing angle.

  As shown in FIG. 12, DBG is the gear meshing circle diameter of the work gear 14, DKG is the tooth tip circle diameter of the work gear 14, DBC is the gear meshing diameter of the phrasing cutter 18, and DKC is This is the diameter of the tip of the phrasing cutter 18. Zg is the number of teeth of the work gear 14, and α is a margin. SKC is the tooth tip width of the processing teeth 32a and 32b of the phrasing cutter 18.

  When the above equation (1) is arranged, the following equation (2) is obtained.

  That is, by setting the axis crossing angle ψ to a value represented by the expression (2), interference of the machining teeth 32a and 32b of the phrasing cutter 18 with the work gear 14 can be more reliably prevented.

  Next, the experimental results of machining by the machining unit 12 of the gear machining apparatus configured as described above will be described.

  FIG. 13 is an enlarged view of the end face corner portion 30 (right tooth surface) obtained by chamfering with the axis crossing angle ψ set to ψ = 0 as in the prior art. As can be understood from FIG. 13, a raised portion 80 due to a surplus is recognized at a location near the chamfered portion (see location 82 in FIG. 8). The height of the raised portion is H1, and the width is H2. The results for the right and left tooth surfaces after a predetermined number of machining operations for ψ = 0 are shown in the column “ψ = 0 °” in Tables 1 and 2. A tracer or the like was used for the measurement.

  FIG. 14 is an enlarged view of the end face corner portion 30 (right tooth surface) chamfered with the axis crossing angle ψ set to ψ = 5 °. As can be understood from FIG. 14, the occurrence of the rising portion 80 is considerably suppressed. The results for the right tooth surface and the left tooth surface obtained by performing a predetermined number of machining operations for ψ = 5 ° are shown in the column “ψ = 5 °” in Tables 1 and 2.

  FIG. 15 is an enlarged view of the end face corner portion 30 (right tooth surface) chamfered with the axis crossing angle ψ set to ψ = 8 °. As can be understood from FIG. 15, the raised portion 80 is almost eliminated. The results for the right tooth surface and the left tooth surface obtained by performing a predetermined number of machining operations for ψ = 8 ° are shown in the column “ψ = 8 °” in Tables 1 and 2. In Tables 1 and 2, the negative value is 0.

  FIG. 16 is an enlarged view of the end face corner portion 30 (right tooth surface) of the 2000th workpiece gear 14 by chamfering the 2000 workpiece gears 14 with the axis crossing angle ψ being ψ = 5 °. is there. As understood from comparison between FIG. 14 and FIG. 16, the rising portion 80 has almost no change between the initial stage and the 2000th. In addition, after 2000 pieces were machined, the shapes of the machined teeth 32a and machined teeth 32b of the phrasing cutter 18 were measured precisely. As a result, no wear was observed compared to the first machining.

  As described above, in the gear machining apparatus, the occurrence of the raised portion 80 can be prevented or considerably suppressed, and the product accuracy is stable even if many machinings are performed, and the phrasing cutter 18 is not worn. Durability was confirmed.

  Next, the analysis result performed about the value of the axis crossing angle (psi) of the process part 12 in the gear processing apparatus comprised in this way is demonstrated.

  As shown in FIG. 17, when the crossing angle ψ is set large, the machining teeth 32a interfere with the teeth 26 of the work gear 14, and therefore, a flank 300 that is substantially parallel to the machining teeth 32a may be provided at the rear end portion. Has been done. By providing such a flank 300, the axis crossing angle ψ can be increased and efficient machining becomes possible. FIG. 17 shows the shape of the machining teeth 32a in which the remaining cutter width S3 is secured with respect to the cutter blade width S in consideration of the interference amount S1 and the gap S2 in consideration of the interference of the teeth 26 of the work gear 14. Yes.

  By the way, it is preferable that the remaining cutter width S3 is 0.4 mm or more from the viewpoint of strength. The gap S2 is preferably set to about 0.5 mm in consideration of errors and the like. Table 3 shows the results of analysis and calculation of the relationship among the axis crossing angle ψ, the interference amount S1, the cutter blade width S, and the remaining cutter width S3 under standard conditions. Here, the gap S2 is 0.5 mm.

  As apparent from Table 3, when the axis crossing angle ψ is 8 °, the remaining cutter width S3 is 0.42 mm, and the strength is ensured. When the axis crossing angle ψ is 9 °, the remaining cutter width S3 is 0.38 mm, and the strength may be insufficient. That is, from the viewpoint of strength, it is desirable that the axis crossing angle ψ is ψ ≦ 8 °.

  When the axis crossing angle ψ is 4 °, it is considered that the remaining cutter width S3 is 0.54 mm and has sufficient strength, but the processing efficiency is lowered. In order to suppress the occurrence of swell of the chamfered portion in the work gear 14, it is considered that the effect is higher as the movement locus of the tooth surface 32 a of the phrasing cutter 18 in the end face corner portion 30 is lateral.

  As shown in the simulation result of FIG. 18A, when the axis crossing angle ψ is ψ = 4 °, the movement trajectory of the tooth surface 32a has a considerably steep slope depending on the place, the lateral component is small, and the rising portion is generated. Suppressive effect is low.

  As shown in the simulation result of FIG. 18B, when the axis crossing angle ψ is ψ = 5 °, the movement trajectory of the tooth surface 32a becomes moderate to some extent, the lateral component exists to some extent, and the effect of suppressing the occurrence of the bulging portion is obtained. is there.

  As shown in the simulation result of FIG. 18C, when the axis crossing angle ψ is ψ = 6 °, the movement trajectory of the tooth surface 32a is considerably gentle, and there are many lateral components, and the effect of suppressing the occurrence of the swelled portion is obtained. high. That is, in order to obtain the effect of suppressing the occurrence of the swelled portion, it is desirable that the axis crossing angle ψ is ψ ≧ 5 °.

  As a result, in order to satisfy the strength and processing effect of the processing teeth 32a, the axis crossing angle ψ is preferably in the range of 5 ° to 8 °.

  Next, the gear machining apparatuses 10a, 10b and 10c having the machining section 12 will be described.

  As shown in FIG. 19, the gear machining apparatus 10a according to the first example simultaneously performs chamfering and shaving of a plurality of work gears 14, and intermittently rotates the work gear 14 every 90 °. A feed table 101, a first stage (first process section) 102 for chamfering the workpiece gear 14 with a phrasing cutter 18, and a second stage for first shaving the workpiece gear 14 ( (Second process part) 104, a third stage (third process part) 106 that performs the second shaving process on the work gear 14, and a carry-in / carry-out stage 108 that replaces the work gear 14. The feed table 101 rotates horizontally, for example.

  The feed table 101 includes four rotation shafts (work support portions) 110a, 110b, 110c, and 110d that can support the workpiece gear 14 at equal intervals (90 °) near the outer periphery, and each is rotated by a motor (not shown). Is possible. The four rotating shafts 110a to 110d may be rotated independently by four motors, or may be rotated by distributing driving force by one motor. Of the rotary shafts 110a to 110d, the one on the loading / unloading stage 108 is stopped for loading / unloading the work gear 14, and the corresponding motor is stopped or the clutch is turned off.

  The first stage 102 is a stage for chamfering the end face corner portions 30 and 31 of the work gear 14, and is provided with the processing portion 12 (see FIG. 1). As described above, the processing unit 12 has the phrasing cutter 18 and meshes the phrasing cutter 18 with the work gear 14 with an axis crossing angle ψ. The phrasing cutter 18 can advance and retreat in the radial direction as viewed from the feed table 101, meshes with the work gear 14 when chamfering the work gear 14, and retracts outward when the feed table 101 is rotated.

  The second stage 104 is a stage for performing the first processing (that is, shaving processing) of the tooth surface 28 of the work gear 14, and includes a shaving cutter 112. The shaving cutter 112 can advance and retreat in the radial direction when viewed from the feed table 101, meshes with the work gear 14 when machining the work gear 14, and retracts outward when the feed table 101 is rotated. The shaving process of the second stage 104 corresponds to rough finishing.

  The third stage 106 is a stage that performs the second processing (that is, shaving processing) of the tooth surface 28 of the work gear 14, and includes a shaving cutter 114. The shaving cutter 114 can advance and retreat in the radial direction as viewed from the feed table 101, meshes with the work gear 14 when machining the work gear 14, and retracts outward when the feed table 101 is rotated. The shaving process of the third stage 106 corresponds to precision finishing. The shaving cutter 114 of the third stage 106 may be the same as the shaving cutter 112 of the second stage 104, or may be a different one suitable for precision finishing.

  The rotary shafts 110a, 110b, 110c, and 110d that support the work gear 14 are configured to be vertical, while the tools of the first stage 102, the second stage 104, and the third stage 106 are It may be provided obliquely so as to have an axis crossing angle ψ. This angle should be adjustable.

  The work gear 14 that has been processed up to the third stage 106 is sent to the carry-in / carry-out stage 108, taken out of the gear processing apparatus 10a, and sent to the next processing (for example, heat treatment processing).

  According to the gear machining apparatus 10a configured as described above, in one apparatus, the first stage 102 performs chamfering with the phrasing cutter 18, and the second stage 104 and the third stage 106 use the shaving cutters 112 and 114. The tooth surface can be processed and is efficient. That is, it is not necessary to transfer the workpiece gear 14 between the chamfering process and the shaving process, and the chamfering process and the shaving process are integrated into one apparatus and save space.

  Further, since the phrasing cutter 18 meshes with the work gear 14 with an axis crossing angle ψ, the end face corner portions 30 and 31 of the work gear 14 are not only crushed and chamfered, but also the crushing surplus. The occurrence of meat swell can be suppressed.

  In addition, the rotation shafts 110a to 110d as work support portions are provided according to the first stage 102, the second stage 104, the third stage 106, and the carry-in / carry-out stage 108, and the three work gears 14 are connected to the first work gear 14. The stage 102, the second stage 104, and the third stage 106 can be processed simultaneously.

  In general, the shaving process takes more time than the chamfering process by the phrasing cutter 18, but the shaving process is performed by dividing it into the second stage 104 and the third stage 106 (or the second process to the N-th process (N ≧ 4)). Thus, the time difference from the first step of the chamfering process can be reduced, and a wasteful waiting time after the first step can be reduced.

  Although the gear machining apparatus 10a has three machining stages except for the carry-in / carry-out stage 108, the number of machining stages for the work gear 14 may be two or four or more. That is, by having at least the first stage 102 and the second stage 104, efficient processing becomes possible. When the number of processing stages is four or more, for example, the shaving processing stage may be divided into three, or a hobbing processing stage may be provided in front of the first stage 102.

  Next, the gear machining apparatus 10b according to the second example will be described. In the description of the gear processing apparatus 10b, the transverse direction is the X direction, the depth direction is the Y direction, and the height direction is the Z direction.

  As shown in FIG. 20, the gear machining apparatus 10b includes a rotary table (rotary base) 202 provided on a base table 200, a work support unit 204 provided on the rotary table 202, a drive board 206, And a tool support 208 provided adjacent to the drive panel 206. In FIG. 20, the operation panel, the lubrication device, the hydraulic power source, the coolant, and the like of the gear machining device 10b are not shown.

  The workpiece support unit 204 includes an X slide base 210 provided on the rotary table 202, an X slider 212 that slides in the X direction with respect to the X slide base 210, and the work gear 14 on the X slider 212 from the left and right. A head stock 214 and a tail stock 216 that are rotatably supported, and a roller cutter unit 220 that is provided in the back in the Y direction and deburrs the work gear 14. The X slider 212 is movable under the action of the X motor 219 in the longitudinal direction of the X slide base 210 (in the X direction when ψ = 0. Hereinafter, it is also simply referred to as the X direction).

  The slide base 210 is provided with a base rotation motor 222. Under the action of the base rotation motor 222, the slide base 210 rotates with respect to the rotary table 202 in a horizontal plane. As a mechanism for rotating the slide base 210 relative to the rotary table 202, for example, a worm wheel mechanism is used. The rotary table 202 is provided with a sensor (for example, a rotary encoder) 224 that accurately measures the amount of rotation of the slide base 210, and the slide base 210 is moved by performing feedback of a fully closed system based on the signal of the sensor 224. Accurate positioning control can be performed. That is, since the amount of rotation of the slide base 210 is directly detected by the sensor 224 instead of indirect feedback based on the amount of rotation of the base rotation motor 222 (so-called semi-closed control), precise control is possible.

  The rotary table 202 is provided with a plurality of (for example, four) clamps 226 that fix the slide base 210 for which positioning control has been completed. The clamps 226 are provided at equal intervals around the rotary table 202 (only one unit is shown in FIG. 20). The rotation of the slide base 210 corresponds to the axis crossing angle ψ, and is configured to be able to rotate, for example, about ± 20 °. When the rotation angle is 0 ° in the reference state, ψ = 0 °, and the axis of the work gear 14 coincides with the X direction.

  The head stock 214 includes one of a sub-slider 230 in the X direction, a shaft support box 232 that can slide in the X direction with respect to the sub-slider 230, a stock motor 234 that drives the shaft support box 232, and one of the work gears 14. And a support shaft 236 that supports this side. The support shaft 236 corresponds to the axis J1. Since the tail stock 216 basically has a symmetrical configuration with respect to the head stock 214, the same reference numerals as those of the tail stock 216 are used and detailed description thereof is omitted. The head stock 214 and the tail stock 216 have different driving forces that move in the X direction. The head stock 214 has a larger driving force, and the head stock 214 defines the position of the work gear 14 in the X direction. The head stock 214 and the tail stock 216 approach and separate when the work gear 14 is attached and detached. The head stock 214 and the tail stock 216 are not provided with a drive source for rotating the work gear 14.

  The roller cutter unit 220 includes two roller cutters 228 arranged in parallel in the X direction, a roller cutter support base 240 that rotatably supports these roller cutters 228, a Y slide base 242, and a Y motor 244. The Y motor 244 advances and retracts the roller cutter support base 240 in the short direction of the X slide base 210 with respect to the Y slide base 242 (in the Y direction when ψ = 0, hereinafter simply referred to as the Y direction). Let The distance between the two roller cutters 228 is adjusted to match the tooth width of the work gear 14, and the flash can be removed by being applied to the work gear 14. The roller cutter unit 220 is not provided with a drive source for rotating the roller cutter 228, and the roller cutter 228 contacts the work gear 14 and removes the flash while rotating. The roller cutter unit 220 is provided on the slide base 210.

  Next, the tool support unit 208 includes a Z slide base 250, a tool support mechanism box 252 that moves up and down in the Z direction with respect to the Z slide base 250, and a turret mechanism 254 that rotates intermittently with respect to the tool support mechanism box 252. Have

  The Z slide base 250 is provided adjacent to the drive panel 206 and extends in the Z direction, and holds the tool support mechanism box 252 so as to be movable up and down in the Z direction. A Z motor 256 that raises and lowers the tool support mechanism box 252 is provided on the Z slide base 250.

  The tool support mechanism box 252 includes an index motor 258 that intermittently rotates the turret mechanism 254 every 60 ° and a spindle motor 260, and has a considerable weight. The tool support mechanism box 252 further includes a positioning pin mechanism and a clutch mechanism (not shown). The turret mechanism 254 can be accurately positioned by the positioning pin mechanism. Power transmission to the turret mechanism 254 can be controlled by the clutch mechanism.

  The turret mechanism 254 is hexagonal when viewed from the side, and rotates every 60 ° in the YZ plane under the action of the index motor 258. In the vicinity of each hexagonal apex of the turret mechanism 254, a first arm 262a, a second arm 262b, a third arm 262c, a fourth arm 262d, a fifth arm 262e, and a sixth arm 262f are respectively directed in the X direction. Is provided. Various tools such as the phrasing cutter 18 can be attached to and detached from these arms 262a to 262f.

  The turret mechanism 254 is configured such that the lowermost one of the six arms 262 a to 262 f is arranged just above the workpiece gear 14. The six arms 262a to 262f are arranged at equal intervals (60 °), and a tool provided on any one of the arms arranged below so as to face the work gear 14 passes through a predetermined clutch mechanism. It can be rotated by a spindle motor 260. The turret mechanism 254 is provided with a tooth surface detection sensor (not shown), and the tool can be automatically engaged with the work gear 14 based on a signal from the tooth surface detection sensor.

  The first arm (first process part) 262 a performs chamfering on the work gear 14 by the phrasing cutter 18, and the support shaft 236 (axis J 1) of the work support part 204 turns the rotary table 202. Therefore, the processing section 12 (see FIG. 1) is formed by the first arm 262a and the support shaft 236.

  When chamfering is performed by the first arm 262a, the two roller cutters 228 are pressed against both ends of the work gear 14 under the action of the Y motor 244 to remove the flash at both ends. Can do. That is, the turret mechanism 254 and the roller cutter unit 220 can approach the work gear 14 from different directions (Z direction and Y direction), respectively, and perform chamfering and deburring simultaneously. The processing time can be shortened. After deburring, the roller cutter 228 is returned to its original position.

  The third arm (second process part) 262 c performs the first shaving process on the work gear 14, and the fifth arm (third process part) 262 e provides 2 to the work gear 14. This is the second shaving process. The second arm 262b, the fourth arm 262d, and the sixth arm 262f are spares. Thus, when three tools are used, the balance of the turret mechanism 254 is improved by providing every other spare. When using two tools, it is good to provide a tool in the position which opposes, and make others the reserve.

  The third arm 262c is provided with a shaving cutter 270 for rough finishing, and the fifth arm 262e is provided with a shaving cutter 272 for precision finishing.

  By the rotation of the turret mechanism 254, the first arm 262a, the third arm 262c, and the fifth arm 262e are sequentially moved to positions facing the work gear 14 of the work support unit 204, and the work gear 14 can be machined. . That is, each tool of the turret mechanism 254 can be moved up and down under the action of the Z motor 256, so when chamfering the work gear 14, the tool is lowered and meshed with the work gear 14 to rotate the turret mechanism 254. Ascend and evacuate.

  When machining the work gear 14, the work gear 14 rotates along with the engagement of the tool of the turret mechanism 254. Therefore, a drive source for rotating the work gear 14 is not required, and the configuration is simple. Since each tool connected to the turret mechanism 254 is larger than the work gear 14, the inertia is large, and the spindle motor 260 is necessarily large to some extent. By using such a large spindle motor 260, the time for accelerating / decelerating the work gear 14 through a tool can be shortened. In other words, since the work gear 14 has relatively small inertia, it easily follows the tool and accelerates or decelerates, and the machining time can be shortened.

  In the gear machining apparatus 10b, hydraulic driving, pneumatic driving, and electric driving are properly used according to the driving location. The axes of the X motor 219, the base rotation motor 222, the Y motor 244, and the Z motor 256 are precisely positioned by NC control.

  When machining the work gear 14, the weights of the tool support mechanism box 252 and the turret mechanism 254 are added to the work gear 14. The weights of the tool support mechanism box 252 and the turret mechanism 254 have a considerable weight, and even if the Z motor 256 does not generate an excessively large force (for example, the current of the Z motor 256 is 0). Even) a sufficient load can be efficiently applied to the work gear 14. As a result, machining can be performed while the workpiece gear 14 is being pressed appropriately, and the workpiece gear 14 can be prevented from being shaken or decentered during machining, and stable machining can be performed.

  According to the gear machining device 10b configured as described above, in one device, the first arm 262a performs chamfering using the phrasing cutter 18, and the third arm 262c and the fifth arm 262e use the shaving cutters 270 and 272. The tooth surface can be processed and is efficient. Further, since the phrasing cutter 18 meshes with the work gear 14 with an axis crossing angle ψ, the end face corner portions 30 and 31 of the work gear 14 are not only crushed and chamfered, but also the crushing surplus. The occurrence of meat swell can be suppressed.

  Furthermore, since the workpiece support unit 204 is provided on the rotary table 202 that adjusts the orientation with respect to the arms 262a to 262f, an appropriate axis crossing angle ψ according to the work gear 14 can be set. .

  The arms 262 a to 262 f of the turret mechanism 254 are in a state having an axis crossing angle ψ with respect to the axis J <b> 2 of the work support unit 204. That is, since the turret mechanism 254 itself is relatively inclined with respect to the axis J2, both the phrasing cutter 18 and the shaving cutters 270 and 272 mesh with the work gear 14 with an axis crossing angle ψ. The individual angle adjustment is not necessary, and the configuration is simple.

  According to the turret mechanism 254, the chamfering process by the phrasing cutter 18 and the tooth surface processes by the shaving cutters 270 and 272 can be performed in one gear processing apparatus 10b, which is efficient. Further, since the shaving process is performed separately for the third arm 262c and the fifth arm 262e, the second process part by the third arm 262c is roughly finished, and the third process part by the fifth arm 262e is precision finished. You can use different tools.

  In the gear machining apparatus 10 b, various tooth surfaces can be formed on the work gear 14 by the simultaneous and coordinated operation of the X motor 219 and the Z motor 256.

  As shown in FIG. 21, like the gear machining apparatus 10 c according to the third example, a third process unit 164 having a shaving cutter 162, a fourth process unit 168 having a shaving cutter 166, and the like separately from the turret mechanism 254. May be provided. That is, a plurality of work support portions 172 are moved by a table 170 similar to the feed table 101, and the work gear 14 is sequentially processed by the turret mechanism 254, the third step portion 164, and the fourth step portion 168. Also good. The workpiece support 172 may be capable of adjusting the axis crossing angle ψ by rotating the tilting mechanism 174 on the table 170.

  According to such a gear machining apparatus 10c, a plurality of work gears 14 can be machined simultaneously by the turret mechanism 254, the third process unit 164, and the fourth process unit 168. The turret mechanism 254 corresponds to the first stage, and performs chamfering by the first arm 154a and rough shaving by the second arm 154b. That is, by performing the finishing shaving process by the third arm 154c in the gear processing apparatus 10b by the third process unit 164 and / or the fourth process unit 168, the shaving process with a long time is performed in a plurality of stages. As a result, the time difference from the first step of chamfering can be reduced, and a wasteful waiting time after the first step can be reduced.

  Next, a gear machining method according to the present embodiment will be described.

  As shown in FIG. 22, in the gear machining method according to the first embodiment, first, in step S101, gear cutting with a hob or the like is performed on the material. By this gear cutting, a schematic shape of the teeth 26 of the work gear 14 is formed, which corresponds to rough finishing of the tooth surface.

  In step S102 (chamfering step), the machining gear 12 chamfers the machining gear 14. As described above, according to the machining section 12, the phrasing cutter 18 is engaged with the work gear 14 with a cross axis angle ψ and chamfers, so that the end face corner parts 30, 31 of the work gear 14 are obtained. In addition to crushing and chamfering, it is possible to suppress the occurrence of excess swell due to crushing. This step S102 is performed using, for example, the gear machining apparatuses 10a to 10c. However, the process proceeds to the next step S103 without performing a tooth surface forming process such as a shaving process.

  In step S103 (heat treatment step), carburizing and quenching by heat treatment of the work gear 14 is performed. This increases the hardness of the work gear 14.

  In step S104 (tooth surface finishing process), gear grinding (gear grinding process) of the work gear 14 is performed. As shown in FIG. 23, the gear grinding process is a process of finishing the tooth surface of the tooth 26 by synchronously rotating a grindstone 180 having a spiral line with the work gear 14. At this time, the work gear 14 is considerably hardened by the heat treatment, but since the chamfering is performed in the chamfering process and the occurrence of the raised portion is suppressed, an excessive load is not applied to the grindstone.

  In step S105 (tooth surface finishing process), gear honing processing (honing process) of the work gear 14 is performed. As shown in FIG. 24, the gear honing process is a process for finishing the tooth surface of the tooth 26 with higher accuracy by rotating the work gear 14 while meshing with the internal grinding wheel 182.

  As described above, in the gear machining method according to the first embodiment, if the heat treatment step is performed without the tooth surface forming after the chamfering step, the number of steps is reduced, which is efficient.

  As shown in FIG. 25, the gear machining method according to the second embodiment includes a gear cutting process (step S201), a chamfering process (step S202), a heat treatment process (step S203), and a gear honing process (step S204) in this order. Have These steps correspond to steps S101, S102, S103, and S105 in the gear machining method according to the first embodiment in FIG. 22, and the gear grinding step in step S104 is omitted.

  Thus, even if the gear grinding step is omitted, the load on the internal grindstone 182 in the gear honing process in the subsequent step S204 is small enough that there is no practical problem. This is because the work gear 14 has a high hardness after the heat treatment, but the occurrence of the raised portion 80 (see FIG. 14) is suppressed. If a large raised portion 80 exists, the portion always abuts against the same portion of the internal grinding stone 182 and only that portion is extremely worn, which is not practical. In the present embodiment, the occurrence of the raised portion 80 is suppressed, and it is possible to prevent an excessive load from being applied only to a predetermined portion of the internal grinding wheel 182.

  Thus, if the gear grinding step is omitted, the number of steps is further reduced, which is efficient.

  As shown in FIG. 26, the gear machining method according to the third embodiment includes, in order, a gear cutting process (step S301), a chamfering process (step S302), a shaving process (step S303, a first tooth surface finishing process), It has a heat treatment process (step S304), a gear grinding process (step S305, second tooth surface finishing process), and a gear honing process (step S306, second tooth surface finishing process). Among these, steps S301, S302, S304, S305, and S306 correspond to steps S101 to S105 in the gear machining method according to the first embodiment of FIG. 22, and the shaving process of step S303 is added.

  Among these, steps S302 and S304 are performed using, for example, the gear machining apparatuses 10a to 10c, and can be performed in one apparatus before the heat treatment, so that it is not necessary to transfer the workpiece gear 14 between apparatuses. Space saving is achieved and it is efficient. The shaving process may be performed in multiple steps. Thereby, the tact time can be shortened as described above.

  In the gear machining method according to the third (and fourth) embodiment, high-precision machining is possible by performing the tooth surface finishing process separately before and after the heat treatment.

  As shown in FIG. 27, the gear machining method according to the fourth embodiment includes, in order, a gear cutting process (step S401), a chamfering process (step S402), a shaving process (step S403, a first tooth surface finishing process), It has a heat treatment process (step S404) and a gear honing process (step S405, second tooth surface finishing process). These steps correspond to steps S301, S302, S303, S304, and S306 in the gear machining method according to the third embodiment of FIG. 26, and the gear grinding step of step S305 is omitted.

  In the gear machining method according to the fourth embodiment, the occurrence of the raised portion 80 (FIG. 14) is considerably suppressed in the chamfering process in step S402, and the shaving is performed in the subsequent step S403. The portion 80 is substantially absent. Therefore, even if the gear grinding step is omitted, the load on the internal grindstone 182 in the gear honing process in the subsequent step S305 is small enough that there is no practical problem.

  In each embodiment, the tooth surface finishing process after the heat treatment is not limited to gear grinding and gear honing, for example, among the processes that can finish the tooth surface in a finishing hob process, a reamer process, etc. Any one or more may be selected according to the condition. In each embodiment, it goes without saying that an end face cutting step, an inner diameter honing step, and the like may be performed as necessary in addition to the specified steps.

  As shown in FIG. 28, in the gear machining method according to the fifth embodiment, the gear cutting process (step S501), the chamfering process (step S502), and the shaving process (step S503, first tooth surface finishing process) are sequentially performed. Have These steps correspond to steps S301, S302, and S303 in the gear machining method according to the third embodiment of FIG. 26, and the heat treatment step in step S304, the gear grinding step in step S305, and the gear honing step in step S306 are omitted. ing.

  Although the gear machining method according to the fifth embodiment does not have a heat treatment step, the gear machining method is sufficiently applicable to a gear whose required accuracy is not relatively high. Further, in the stage of the shaving finishing process (step S503) performed after the chamfering process (step S502), since the raised portion is hardly generated, the load on the shaving cutters 112, 114, etc. is small and the tool life is extended. Can do. Thereby, while reducing the frequency | count of stopping the gear processing apparatuses 10a-10c for a tool exchange operation | work, and the frequency | count of a maintenance and an inspection, tool cost can be suppressed.

  As shown in FIG. 29, the gear machining method according to the sixth embodiment includes, in order, a gear cutting process (step S601), a chamfering process (step S602), a shaving process (step S603, a first tooth surface finishing process), And a heat treatment step (step S604). These steps correspond to steps S301, S302, S303, and S304 in the gear machining method according to the third embodiment in FIG. 26, and the gear grinding step in step S305 and the gear honing step in step S306 are omitted. .

  The gear machining method according to the sixth embodiment does not have a tooth surface finishing step after the heat treatment step, but has a sufficient durability because the hardness of the work gear 14 is increased by the heat treatment step. Applicable to gears with low accuracy. Of course, if the tooth surface finishing step after the heat treatment step is performed as in the third embodiment, it is more suitable for a gear of a highly accurate vehicle transmission.

  In each embodiment, the tooth surface finishing process after the heat treatment is not limited to gear grinding and gear honing, for example, among the processes that can finish the tooth surface in a finishing hob process, a reamer process, etc. Any one or more may be selected according to the condition. In each embodiment, it goes without saying that an end face cutting process, an inner diameter honing process, and the like may be performed as necessary in addition to the specified processes.

  As described above, in the gear machining method according to the present embodiment, since the phrasing cutter 18 meshes with the work gear 14 with the axis crossing angle ψ, it is pushed against the end face corner portions 30 and 31 of the work gear 14. In addition to crushing and chamfering, it is possible to suppress the surging of the surplus due to crushing.

  The gear machining method according to the present invention is not limited to the above-described embodiment, and it is needless to say that various configurations and processes can be adopted without departing from the gist of the present invention.

It is a schematic perspective view of the process part of a gear processing apparatus. It is a perspective view of a work gear. It is a perspective view of a phrasing cutter. It is an expansion perspective view of the meshing part of a phrasing cutter and a to-be-cut gear. It is the schematic diagram which each developed the to-be-cut gear and the phrasing cutter along the surrounding surface. It is the schematic diagram which each developed the to-be-cut gear and the phrasing cutter along the surrounding surface in the meshing state which concerns on a prior art. FIG. 7A is a schematic perspective view of the meshing portion at the initial stage of meshing, FIG. 7B is a schematic perspective view of the meshing portion at the middle of meshing, and FIG. 7C is a schematic perspective view of the meshing portion at the end of meshing. It is a schematic perspective view of the right tooth surface after a process. FIG. 9A is a diagram showing the movement trajectory of the tooth surface of the phrasing cutter at the end face corner when the axis crossing angle is 5 °, and FIG. 9B is the phrasing cutter at the end face corner when the axis crossing angle is 8 °. It is a figure which shows the movement locus | trajectory of this tooth surface. It is a schematic perspective view of the left tooth surface after a process. It is the schematic diagram which expanded the part of the cut gear and the phrasing cutter along the peripheral surface. It is an enlarged side view of the meshing part of a phrasing cutter and a to-be-cut gear. It is an enlarged view of the end face corner portion of a work gear machined with an axis crossing angle of 0 °. It is an enlarged view of the end face corner part of the to-be-cut gear processed by setting an axis crossing angle as 5 degrees. It is an enlarged view of the end face corner part of the to-be-cut gear processed by making an axis crossing angle into 8 degrees. It is an enlarged view of the end face corner portion of the 2000th workpiece gear when the axis crossing angle is 5 ° and machining is performed 2000 times. It is a schematic diagram which shows the relationship between the tooth | gear in a phrasing cutter, an axis crossing angle, a cutter tooth tip width | variety, an interference amount, a clearance gap, and a cutter remaining width. FIG. 18A is a diagram showing the movement trajectory of the tooth surface of the phrasing cutter at the end face corner when the axis crossing angle is 4 °, and FIG. 18B is the phrasing cutter at the end face corner when the axis crossing angle is 5 °. FIG. 18C is a diagram showing the movement trajectory of the tooth surface of the phrasing cutter at the end face corner when the axis crossing angle is 6 °. It is a top view of the gear processing apparatus which concerns on a 1st example. It is a perspective view of the gear processing apparatus which concerns on a 2nd example. It is a top view of the gear processing apparatus which concerns on a 3rd example. 3 is a flowchart of a gear machining method according to the first embodiment. It is a schematic diagram which shows the mode of a process of a gear grinding process. It is a schematic diagram which shows the mode of a process of a gear honing process. It is a flowchart of the gearwheel processing method which concerns on 2nd Embodiment. It is a flowchart of the gearwheel processing method which concerns on 3rd Embodiment. It is a flowchart of the gearwheel processing method which concerns on 4th Embodiment. 10 is a flowchart of a gear machining method according to a fifth embodiment. It is a flowchart of the gearwheel processing method which concerns on 6th Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10a, 10b, 10c ... Gear processing apparatus 12 ... Processing part 14 ... Workpiece gear 18 ... Phrasing cutter 26 ... Teeth 28 ... Tooth surface 30, 31 ... End face corner part 32a, 32b ... Processing tooth 80 ... Swelling part 101, 170 ... Table 102 ... 1st stage (1st process part) 104 ... 2nd stage (2nd process part)
106 ... Third stage (third process section) 108 ... Loading / unloading stages 110a to 110d ... Rotating shaft (work support section)
112, 114, 162, 166, 270, 272 ... Shaving cutters 172, 204 ... Work support 202 ... Turntable (turntable)
220 ... roller cutter unit 224 ... sensor 228 ... roller cutter 234 ... stock motor 236 ... support shaft 252 ... tool support mechanism box 254 ... turret mechanism 262a to 262f ... arms J1, J2 ... axis ψ ... axis crossing angle

Claims (18)

A chamfering step of chamfering an end face corner portion of the gear to be cut by rotating the phrasing cutter with the gear to be cut with an axis crossing angle ψ;
After the chamfering step, a heat treatment step of heating the work gear without tooth surface molding, and
After the heat treatment step, one or more tooth surface finishing steps for forming a tooth surface of the work gear;
A gear machining method comprising: The gear machining method according to claim 1,
A gear machining method, wherein the tooth surface of the phrasing cutter is an involute surface having no corner as a cutting blade. The gear machining method according to claim 1 or 2,
The gear surface finishing process is any one or more of a finishing hob process, a gear grinding process, a honing process, and a reamer process. In the gear machining method according to any one of claims 1 to 3,
A workpiece support that pivotally supports the work gear,
A cutter support portion that pivotally supports the phrasing cutter so as to mesh with the work gear provided on the workpiece support portion;
Use
The said cutter support part meshes the said phrasing cutter with the to-be-cut gear with an axis crossing angle (psi), The gear processing method characterized by the above-mentioned. The gear machining method according to claim 4, wherein
The gear working method according to claim 1, wherein the work support portion is provided on a turntable that adjusts a direction with respect to the cutter support portion. In the gear machining method according to any one of claims 1 to 5,
A gear machining method, wherein the work gear is a helical gear. The gear machining method according to claim 6, wherein
The gear machining method, wherein the work gear is a gear of a vehicle transmission. A chamfering step of chamfering an end face corner portion of the gear to be cut by rotating the phrasing cutter with the gear to be cut with an axis crossing angle ψ;
After the chamfering step, one or more first tooth surface finishing steps for forming a tooth surface of the work gear without heat treatment;
A gear machining method comprising: The gear machining method according to claim 8, wherein
The gear tooth machining method, wherein the first tooth surface finishing step is a shaving step. The gear machining method according to claim 8 or 9,
A gear machining method comprising a heat treatment step of heating the workpiece gear after the first tooth surface finishing step. The gear machining method according to claim 10, wherein
A gear machining method comprising one or more second tooth surface finishing steps for forming a tooth surface of the work gear after the heat treatment step. The gear machining method according to claim 11, wherein
The gear tooth machining method, wherein the second tooth surface finishing step is any one or more of a finishing hob step, a gear grinding step, a honing step, and a reamer step. In the gear machining method according to any one of claims 8 to 12,
A workpiece support portion that pivotally supports the work gear;
A first process part and a second process part that move relative to the work support part and perform processing in order;
Using a gear machining device comprising
The gear machining method according to claim 1, wherein the chamfering step is performed in the first process portion, and the first tooth surface finishing step is performed in the second process portion. The gear machining method according to claim 13, wherein
The gear machining apparatus has a third process unit that moves relative to the workpiece support unit and processes the work gear after machining in the second process unit,
The third process unit includes a shaving cutter that processes a tooth surface of the work gear,
There are at least three workpiece support sections corresponding to the first process section, the second process section, and the third process section, and the three work gears are arranged in the first process section and the second process section. And the gear processing method characterized by processing simultaneously by the said 3rd process part. The gear machining method according to claim 13, wherein
The first process part and the second process part are provided in a turret mechanism, and move to a position facing the workpiece support part in order by the rotation of the turret mechanism to process the work gear. Processing method. The gear machining method according to claim 15, wherein
The gear machining method according to claim 1, wherein the rotation shaft of the turret mechanism has an axis crossing angle ψ with respect to the axis of the workpiece support portion. The gear machining method according to claim 15, wherein
Provided separately from the turret mechanism, having a third process part that moves relative to the work support part and processes the work gear after processing in the second process part,
The third process unit includes a shaving cutter that processes a tooth surface of the work gear,
At least two workpiece support parts are provided according to the turret mechanism and the third process part, and the two work gears are simultaneously processed by the turret mechanism and the third process part. Gear machining method. The gear machining method according to claim 15, wherein
A third process part that moves relative to the workpiece support part and processes the work gear after machining in the second process part;
The third process unit includes a shaving cutter that processes a tooth surface of the work gear,
The gear machining method according to claim 1, wherein the phrasing cutter of the first process part, the shaving cutter of the second process part, and the shaving cutter of the third process part are provided in the turret mechanism.

Images