Gear gear machining

The double countershaft transmission plays a huge role in the heavy-duty vehicle market due to its good transmission performance and large carrying capacity. Due to its structural requirements, the gears on the intermediate shaft need to be machined to the teeth, and the degree of the pair is directly affected, which directly affects the assembly quality of the transmission, thereby affecting the performance of the entire transmission. According to the company's new product processing needs, this paper designs a simple tooth-toothing device, which can stabilize the internal and external tooth symmetry, and has a simple structure and convenient operation, which is widely praised by users.

Process flow

Figure 1 Intermediate shaft second gear

The second gear of the transmission intermediate shaft of a certain type of our company adopts the internal spline cogging and the outer ring gear tooth symmetry structure, and the symmetry requirement is within 0.06mm (see Figure 1). To meet product design requirements, we use the following process:

(1) The inner spline has a small hole diameter due to the inner spline. For example, the shape of the pinion cutter is small, and the number of teeth of the pinion cutter is small, and the spline quality of the workpiece after machining is poor. The knife has a low life and low processing efficiency. Therefore, we use the broaching process of broach with high processing efficiency and high processing precision.

(2) The outer ring gear is used to ensure the machining accuracy of the outer ring gear. The process of shaving the teeth after the teeth is selected, so that it is necessary to design a set of gear-to-tooth clamps for inserting the outer ring gear.

2. Analysis of the tooth problem

According to the product design requirements, after the workpiece is processed, it must be ensured that one tooth groove of the inner spline is symmetrical with one tooth groove of the outer ring gear. We select a tooth groove of the inner spline to position, and then make a certain cutting edge of the pinion cutter just cut off. The outer ring gear metal (see Figure 2) opposite the internal spline positioning groove can achieve the symmetry requirement of the workpiece after machining.

Figure 2 shows the gear shaping

3. Solve the problem of teeth

In order to meet the requirements of the gear-toothing of the product, we designed the tooth clamp as shown in Figure 3. The structure is a spline groove positioning method in the workpiece. The ball is fixed on the slider and the slider is spring. drive. When using, push the handle by hand, load the workpiece, loosen the handle, and slightly rotate the workpiece by hand, so that the ball is fixed in the internal spline tooth groove, so that the circumferential direction of the workpiece is well positioned, and then the sleeve is tightened to realize the workpiece setting. Heart and tension.

Figure 3 pinion to tooth fixture

In the first round of trial production, a total of 50 workpieces were put into production. After the machine tool and the toothed fixture were debugged, 45 workpieces were continuously processed, all of which were measured for symmetry, and the symmetry was stable within 0.06 mm. Meet the on-site production needs.

4. Conclusion

Through field practice, after the outer ring gear is machined by the machining process scheme and the gear shaping jig, the symmetry can be stably controlled within 0.06, which fully satisfies the mass production of the workpiece.

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