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The Design and Simulation of Roller for Machining Involute Spline
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The involute spline made by cold-rolling have many advantages. This method can increase the production efficiency, save material, prolong the cutting tool’s life, and improve the dimensional accuracy. Because the metal fiber continues between the spline’s teeth, wearing resistance of the spline’s teeth side is better and intensity of the teeth is higher. The cold rolling is the development trend of involute spline manufacturing. And the design of the roller is the key point in the cold rolling processing. This paper analyses the principle of cold rolling for involute spline and sets up the design model of roller. Because of the plastic deformation, the amendment method is introduced according to experiment data. On the basis of research of the main algorithm, the roller CAD system is developed for the involute spline and the roller simulation system is built. The roller CAD system and the simulation system have been put into practice and the roller design model and the amend method proved to be correct in the practice. The application meets the urgent need in the spline manufacturing. Index Terms - involute spline; roller; design model; CAD simulation.6953
I. INTRODUCTION
As an important link method, the involute spline shaft is used widely in automobile and tractor. The involute spline can be made by teeth-milling, hobbing, gear-shaping and broaching in traditional manufacturing. As compared with the traditional method, cold rolling has many advantages: saveing material, prolonging the cutting tool’s life, increasing the production efficiency and improving the dimensional accuracy. Because the metal fiber continues between the spline’s teeth, wearing resistance of the spline’s teeth sides is better. So the cold rolling is regarded as the development trend in involute spline manufacturing. In the process of cold rolling, a pair of rollers with certain shape strike the shaft blank continually and the plastic deformation is made. So the correct spline teeth are built in the blank.The rollers are installed on two eccentric axles respectively which are coupled to revolving axles with high speed. The two axles rotate in step in different direction .The rollers strike the blank once each round. The two rollers rotateat the moment when they touché the blank. In the rolling process, the part rotates for side set and feeds in the axial direction as Fig.1 shows. In the moment of the rollers strike the blank, the shaft blank rotates continually and feeds along its own axis. So the process can be seen as rolling method with continual side-set. In the process of rolling, the rollers revolve around axis with high speed and the shaft blank rotates continually and feed along its own axis. So the surface extruded by the rollers is helicoids. As mentioned above, rolling is nether generating method nor spread-blade cutting method. In the research of roller design in China, the main method is mapping the inward roller and making use of the mapping data in roller design, which is difficult for machining. Another method is to make the shape of roller fit the outline of the spline, which base on the assumption that the axial section of roller fit to end surface section closely. But the fact that the motion at the moment is spread-blade cutting method was ignored. So the design model of roller deviates and the accuracy of the involute spline are affected further.
Fig.1 The joggling relation between the involute spline and the roller
In this paper, the roller model is built based on the analyses of motion between the roller and the spline and the formation principle of equi-pitch helicoids. The amendment project for design model is brought forward through the calculation method based on experimental data. The roller CAD system and the simulation system for roller grinding are developed on the research above mentioned.
II. THEMATHEMATICAL MODEL OF ROLLER
According to the principle of cold rolling for involute spline , the model of axial section is the main body in roller design. Given that the outline of ideal involute spline consists of six curves:the involute spline on the side ,the curve on the root of teeth and the transition curves between them. The involute spline on each side of teeth is symmetrical about the center line of the tooth space and can be seen as the right involute spline and the left involute spline. In the same way, the curve on the root of tooth is symmetrical about the center line too, which can be shown in Fig. 2.