Course Design Cutting Tool - Shaped Cutter and Link Kit

Contents

Introduction

Job for Course Project

1 Design of shaped cutters

1.1 Brief theoretical information

1.2 Setting of the task

1.3 Preparation of initial data

1.4 Design Algorithms for Shaped Cutters

1.8 Cutter calculation

2 Screw cutter design for spline shaft

2.1 Theoretical information

2.1.1 General System Information

2.1.2 Main Menu

2.1.3 Organization of user dialogue in the system

2.1.4 Setting of calculation and checking of cutter parameters

2.1.5 Start and order of cutting design

2.1.6 Design Start

2.1.7 Setting initial data

2.1.8 Profile calculation

2.1.9 Design calculation

2.1.10 Receipt of documentation

2.1.11 Calculation of milling cutter design for all types of worm cutters

2.1.12 Receipt of documentation

2.1.13 Calculation of profile of worm gear cutters for cylindrical gears with involute profile

2.1.14 Calculation of the profile of worm cutters for cutting shafts with a straight-flow (and involute) profile of teeth located parallel to the spline joint axis

2.1.15 Calculation of worm cutter profile for sprockets

2.1.16 Calculation of worm cutters for parts with non-standard profile. Spikelets shafts

2.1.17 Gear worm cutter design example

2.1.18 Screw Cutter Design Example for Spline Shaft

2.1.19 Creation of documentation

3.1 General provisions

2.2 Mill Profile Calculation Results

(Straight-flow spline shaft, series of splines - medium)

2.2 Mill Profile Calculation Results

(Straight-flow spline shaft, series of splines - medium)

3 Design of disk shaped cutter

3.1 General provisions

3.2 Understanding Tools

3.3 Structure of tools for automated machine building

3.4 Tool for CNC and HA Machines

3.5 Task

3.6 Theoretical information

3.7 Calculation sequence of disk shaped cutters for processing screw spiral drills

3.8 Construction of profile of shaped cutter

3.9 Calculation of disk shaped cutter

4 Drawing Kit Design

4.1 General Information About Sweeps

4.2 Calculation of the track set

4.3 Optimization of the extension unit

4.4 Operation of trails

List of literature

Application

Introduction

The purpose of this work is to design and calculate a metal cutting tool.

The profile of the cutting tool features is calculated using a computer. In the course of this work, both the direct and the reverse task of designing a tool is solved. It is proposed to design a round shaped cutter and a disk groove cutter for processing drill grooves, a worm cutter for processing a splined shaft and a set of rails.

The calculation of the shaped cutter, the worm cutter for processing the splined shaft and the disk shaped cutter is carried out on a personal computer. After calculating and entering the initial data on their basis, drawings for the above tools are developed.

The drawing kit is developed manually and calculated in Microsoft Office Exell 2007.

The programs and methods were compiled by Vasily Pavlovich Prokopiev.

Calculation of worm cutter for splined shaft treatment is performed on the specialized product COMPASS 8PLUS

Performing this work allows you to gain knowledge of the design of a cutting tool, new practical data of working with computers in solving a specific task.

Main Menu

Once started, the main application window is displayed. The main window is divided into two fields containing the main menu and toolbar.

The main system menu is a standard system control tool. To speed up work, some menu items are duplicated on the toolbar. You can select menu items using the mouse or keyboard.

Use the toolbar to quickly access commands. Each button on the toolbar corresponds to one of the main menu items.

Organize a user dialogue in the system.

The dialogue is organized on the basis of the following requirements:

1. One window implements a single subassembly solution or

Placing data that is merged into a single subtask

(interrelated by formulae of ratios);

2. Data entry fields must be accompanied by a pop-up window with

explanatory information (parameter name, minimum and

maximum permissible values);

3. Texts highlighted in blue are accompanied by explanatory

information, not accompanied - in black;

4. If possible, drawings with dimensioning on them were used.

For example, by selecting the precision class of the cutter, placing the mouse cursor on the

a yellow window with reference information from the

standard.

When you edit the value of the trailing angle at the vertex by moving the mouse cursor to a rectangular frame, a yellow window appears with the minimum and maximum allowable value. Immediately, the rear angle on the side is calculated and checked (the value of the value is highlighted in blue). Moving the mouse cursor to the value of the quantity, a yellow window appears with the minimum allowable values ​ ​ of this angle.

Set up calculation and checking of cutter parameters.

From the main menu, select Options/Worm Mills.... The system proposes to adjust the values ​ ​ of the following coefficients that affect the calculation and fulfillment of the specified conditions: the ratio coefficient of the mounting diameter and dangerous section, the ratio coefficient of the height and width of the mill tooth. For straight splined shafts it is possible to select the factor of the shaft size tolerance.

Recommendations. The ratio of height and width of the tooth is 0.5 - large modules, 0.75 - small modules, the ratio of the mounting diameter and dangerous section is 0.25 - gears, 0.3 - 0.35 - splines and sprockets, the tolerance value is 0.5 for finishing cutters with small tolerances for the width of the spline, 0.25 for draft with a large tolerance.

Start and order of cutting design.

From the main menu, select the desired project or click the corresponding icon. Before designing, the system prompts you to specify the working directory and the name of the results file. The results file will be

Contain all specified and calculated data that will be entered in the documentation templates.

The design process consists of the following steps:

- setting initial data;

- definition of mill parameters from standards;

- calculation of tooth geometry;

- calculation of design dimensions of the cutter;

- creation of documentation;

- checking of cutter profile, (short circuit module)

In cases of design of non-standard parts (sharp-splined shaft), the stage of graphic design of the cutter profile by the part profile in KZ module is added.

Design Start

- Create a C: Test directory on disk to perform the exercises.

- Start SAPRFREZ.

- From the main menu select Project/Worm cutters for.. ./Spline shafts

- At the system prompt, select the C: Test directory and type the name of the results file. (For this example, file _ 002).

- Click Save.

Specifying Initial Data

- In the Mill Settings dialog box, specify the following options:

1. Cutter for shaft - medium series.

2. Accuracy class - A.

3. The nominal size of the series is 8x52x60.

- Click Accept.

- In the Spline Shaft Settings dialog box, specify the following parameters:

1. Centering by... - d, execution A.

2. Spline thickness - 10 (0; 0.1); outer diameter - 60 (0; 0.1).

3. Internal diameter - 52 (0.2; 0); chamfer - 0.4 (0.2; 0).

4. The minimum length of the platform, and - 2.4.

- Click Accept.

- In the Profile Tangent dialog box, specify the following parameters:

1. Accept: - profile step.

2. Profile pitch, tn - 23 mm.

- Click Accept.

Profile Calculation

- The First Validation Method window displays the basic profile parameters.

- Click Accept. The system will check the second method and present the results.

- In the Mill Tooth Thickness dialog box, click the free square and the system prompts for the height parameter.

- In the Height dialog box, specify the height hx from the start. lines - 2 mm. Click Accept.

- After obtaining the tooth thickness result, click Next.

In the Mill Profile window, click Accept.

- In the Tooth Angles dialog box, click Accept.

Design Calculation

- In the Tooth Geometry dialog box, specify the following parameters:

1. The value of the tooth nape is 5.

2. The value of the double occlusion is 6.5.

3. The height of the mill tooth is 14.5.

- Click Accept. The system performed a check calculation and in cases of insufficient dangerous cross-section proposed 3 options: take the angle of the grooves 0 °, reduce the diameter of the landing hole or change the parameters.

- In the Keyway window, click Accept.

- In the Design Dimensions window, change the length of the fit hole 23 to 25.

- Click End Calculations.

- When prompted for mill number, enter 00002.

- Click Accept.

Obtaining documentation

- From the main menu, choose Documentation/Create Documentation. - At the system prompt, select the C: Test directory and select the file _ 002.rzl result file.

- Click Open. Please wait while the system generates the "Documentation Created" message.

- After the documentation is created, the C: Test directory contains the text file shb2.txt (opened by any text editor) and graphic files: fsh.cdw and fsh.cdw; read the generated documentation.

- For example, from the CAD FREZ main menu, select Documentation/Text Editor and open the shb2.txt file. From the CAD FREZ main menu, select Project/Exit and view the drawings you created in COMPASS GRAPH (fsh.cdw and fsh.cdw files).

Calculates the mill design for all types of worm cutters.

The front angle is selected depending on the operating conditions: for finishing cutters 0 °, for draft cutters 5 °... 10 °.

The trailing angle at the apex of the teeth is selected to provide a minimum trailing lateral angle of the cutter.

Tooth geometry parameters are interconnected. For example, if you change the backlash factor, the additional backlash factor and groove depth are recalculated at the same time. The proportion of tooth height and thickness is also analyzed. The proportion is set in the system settings.

Receiving documentation.

From the file of results and templates (the files shbl.txt, shbll.txt, shb2.txt, shb3.txt, shb4.txt, txt_pr.txt, FKl.cdw, FK21.cdw, FK22.cdw, FK3.cdw, FK41.cdw, FK42.cdw, FN.cdw, FSH.cdw, FSHl.cdw, FSH2.cdw, FZ.cdw in the catalog. / SAPRFR/DOC/...) it will be created text (*.txt) and the graphic (*.cdw) file of documentation.

From the main menu, choose Documentation/Create Documentation.

- At the system prompt, select the * .rzl results file.

Click Open. Please wait while the system generates the "Documentation Created" message.

- After the documentation is created, the directory will contain a text file

* .txt (opened by any text editor) and graphic file * .cdw;

read the created documentation.

For example, from the CAD FREZ main menu, select Documentation/Text Editor and open the * .txt file. From the CAD FREZ main menu, select Project/Exit and view the drawings created in COMPASS-PLOT (* .cdw).

- Save the drawing.

If you want to customize templates for enterprise conditions, use the text editor (* .txt templates) and the COMPASS GRAPH graphic editor (* .cdw templates).

Calculating the Profile of Worm Tooth Cutters for

Cylindrical gears with involute profile.

Worm cutter for cutting wheels with involute profile is theoretically correct if it is made on the basis of worm with involute profile of turns in section perpendicular to its axis.

The Gear Settings dialog box sets the basic initial parameters. In case of mill design with modification additional

parameters are set in the Modify Profile for Chevering window. In the Initial Mill Data window, specify the basic mill parameters. The radial clearance is usually 0.25 t.

After you specify all the parameters, we proceed to calculate the profile and design dimensions of the mill.

Displays the basic dimensions of the profile and allows you to refine the radii of the profile troughs and vertices as needed.

Under the sketch, new parameters are displayed in cases of a reduced mill profile.

Flanking of the cutter profile shall ensure cutting of the wheel tooth head within the specified limits. The optimal shear values are experimentally found on a case-by-case basis, but usually the shear sizes for the gears of the modules from 2 to 6 mm to be shevered are accepted within the limits: height - f = 0.5... 0.8 mm, width - q = 0.1... 0 3mm.

Calculation of the profile of worm cutters for cutting shafts with a straight (and involute) profile of teeth located parallel to the spline joint axis.

The main sizes of splined joints are regulated by GOST 113980, which provides for three series of connections - light, medium and heavy.

The mill profile can be determined analytically, graphically and graphically analytically. The graphical method is implemented using the short-circuit system. It is recommended to use it when obtaining a profile for non-standard parts (sharp splined shafts, etc.) or non-standard splined shaft profiles (with an uneven grinding allowance), as well as for checking analytical calculation. For standard spline shaft profiles, the analytical method is recommended. Graphoanalytic method involves the combination of analytical calculation with graphical constructions

All mill data is set depending on the splined shaft parameters. For standard shaft series, ZxdxD values ​ ​ are selected from a series, and for non-standard ones they are set separately. Precision class A and B for finish cutters, C for draft cutters.

A - for final cutting of shafts with tolerance fields for thickness of teeth 69, h9, e9, f9 and tolerance fields for centering diameters: internal e8 and external - according to GOST 113980;

C - for final cutting of shafts with tolerance fields for tooth thickness dlO and tolerance fields for centering diameters: internal - e9 and external - according to GOST 113980;

C - for rough cutting of shafts.

Almost this curve is replaced by arcs of one or more

circles. A circle is defined by three or four points. One of the points is at the origin, the position of the others is determined by the angles al, a2, aZ. The angles for the intermediate points are adjusted to select the optimal position, and by clicking the Recalculate button, the new coordinates are calculated and checked according to the first method. Click the Accept button and the system will perform the second method check.

The absolute sum of deviations from the theoretical profile curve shall not exceed 2/3 of the spline width tolerance. If the error value is greater than the permissible value, then you should recalculate the profile again, given by other angles, get other points. If in this case the error value is greater than permissible, then the theoretical profile should be replaced by arcs of two circles. It should be noted that if the profile height is greater than 12% of the radius of the outer diameter of the roller, replacing the theoretical curve with an arc of one circle gives too large deviations.

The second verification method was adopted at the Lviv Tool Plant (LIZ). It is more accurate and consists in increasing the number of checked points of the cutter profile, calculated according to the original method.

The system calculates up to eight mill profile control thicknesses. At the vertex, start line, and flange, the thickness is calculated automatically. Additionally, the reference spline thickness is calculated at the height of the antennae (spline type A) and at the height of the conjugate point of the two arcs. The remaining profile control points are additionally calculated (if desired) when the height from the vertex or from the start line is set accordingly.

The Mill Profile window displays the profile dimensions so that you can change the width, groove depth, and flange angle.

Calculates the worm cutter profile for sprockets.

To calculate the sprocket, the following parameters are specified: pitch, diameter of the chain engagement element, the precision class of the mill, the number of sprocket teeth and the presence of mixing of the center of the recesses arcs.

The system automatically calculates the full dimensions of the mill profile. In case of setting of non-standard initial data (not from GOST 59169) additional profile check is required in KP module.

Calculates worm cutters for parts with a custom profile.

Spikehead shafts.

The solution of the problem is divided into two stages: a graphical definition of the profile of the cutter; analytical calculation of cutter structural dimensions.

The SC module is used to graphically define the profile. Using the Compass Graph graphics system, you create a graphic file with a part profile (file extension * .frg). After starting of short circuit module and

The corresponding library is called to import the graphic file. The library populates the required parameters and starts the process simulation. The graphics run-in time depends on your computer configuration and profile complexity and can take 10 minutes to 3 hours or more. At any time, you can stop the model and save the results, export the profile to a graphic file for Compass Plot. See non-standard worm cutter design example.

Example of design of worm cutter for gear wheel.

Design Start

- Create a C: Test directory on disk to perform the exercises.

- Start SAPRFREZ.

From the main menu, select Design/Worm Cutters for .../Gears

At the system prompt, select the C: Test directory and type the results file name. (For this example, flleOOl).

- Click Save.

Initial data setting The system implements the design of cutters for modules from 1 to 20 mm with the possibility of designing the module value not from the standard row and profile angle from 15 ° to 30 °.

- In the Gear Settings dialog box, specify the following parameters:

1. The gear module is 3.38 mm.

2. The profile angle of the initial contour of the wheel is 22.5 °.

3. Line of teeth - Left

4. The tooth thickness of the wheel is 6.65 mm.

5. The outer diameter of the wheel is 55.60 mm.

6. The diameter of the dividing circle is 45.710757 mm.

7. The diameter of the circumference of the depressions is 40 mm.

- Click Accept.

- In the Initial Mill Data window, specify the following options:

1. Worm cutter - finished.

2. The type of cutter is 2.

3. Execution - normal length.

4. Accuracy class - A, with modification.

5. Allowance value - 0.060 mm.

6. The number of cutter entries is 1.

7. Radial clearance factor is 0.25.

- Click Accept.

In the Modify Shear Profile dialog box, specify the following options:

1. Profile modification: shrunk profile angle, antennae, flanges.

2. The new profile angle is 15 ° 00.

3. Number of wheel teeth, zl - 13.

4. Angle of wheel teeth inclination, b 16 °.

5. Dividing diameter of the conjugated wheel, 62-85 mm.

6. The diameter of the vertices of the hide wheel, D2 - 88 mm.

- Click Accept.

Profile Calculation The Normal Section Tooth Profile window displays the basic profile parameters.

- Click Accept.

- In the Mill Antennae Calculation window, change the angle of the antennae 5 to 8. In

as a result of changing the angle, the width area will be less than 0.5 mm

and the system will select a second type of antennae.

- Click Accept.

- In the Mill Flange Calculation dialog box, change the flange angle from 30 ° to 46 °.

- Click Accept.

- In the Tooth Angles dialog box, click Accept.

Design Calculation In the Basic Design Dimensions dialog box, specify the following parameters:

1. The outer diameter of the cutter is 63 mm.

2. The diameter of the mounting hole is 22.

- Click Accept.

- In the Tooth Geometry dialog box, specify the following parameters:

1. The value of the tooth nape is 3.5.

2. The value of the double occlusion is 4.5.

3. The height of the mill tooth is 14.

- Click Accept. The system performed the check calculation and in

cases of insufficient value of hazardous section suggested 3 options: angle

take grooves 0 °, reduce the diameter of the fitting hole or change

options.

- Select groove angle w = 0 °.

- Click Accept.

- In the Keyway window, click Accept.

- In the Design Dimensions window, click End Calculations.

When prompted for the mill number, specify the number 00001 or the text encoding of the mill.

- Click Accept.

Obtaining documentation

- From the main menu, choose Documentation/Create Documentation.

- At the system prompt, select the C: Test directory and select the file _ 001.rzl result file.

Click Open. Please wait while the system generates the "Documentation Created" message.

Once the documentation is created, the C: Test directory will be located

text file shbll.txt (opened by any text editor) and graphic file fk42.cdw; Review the documentation created.

For example, from the CAD FREZ main menu, select Documentation/Text Editor and open the shbll.txt file. From the CAD FREZ main menu, select Project/Exit and view the drawings created in COMPASS-PLOT (fk42.cdw file).