Device and method for manufacturing crown gear

Abstract

The inventive device includes a work supporting portion for supporting a work rotatably about a first axis, a cutter supporting portion for supporting a cutter rotatably about a second axis different from the first axis and a moving portion for moving the cutter along a reference line extending through the first axis. The second axis is slanted relative to a reference plane oriented perpendicular to the first axis and a blade edge of the cutter is caused to come into contact with the work at an offset position offset from the reference line. The work and the cutter are driven in synchronism and the cutter is moved along the reference line.

Claims

1. A device for manufacturing a crown gear comprising: a work supporting portion for supporting a work rotatably about a first axis; a cutter supporting portion for supporting a cutter rotatably about a second axis different from the first axis; a synchronized driving portion for rotating the work supporting portion and the cutter supporting portion in synchronism with each other; and a moving portion for moving the cutter supporting portion relative to the work supporting portion; wherein the second axis is disposed under a set posture along a reference line passing through the first axis and set at an offset region offset from the reference line as viewed along a direction parallel with the first axis and the second axis is disposed under a posture slanted relative to a reference plane extending perpendicular to the first axis, whereby the work supporting portion and the cutter supporting portion are configured to cause a leading end of the cutter to contact with the work at the offset region at an angle relative to a rotational plane of the work; the synchronized driving portion rotates the work supporting portion and the cutter supporting portion in synchronism in such a manner to move an outer circumference of a blade edge at the leading end of the cutter in a direction same as a rotational direction of the work; the moving portion moves the cutter in a direction along the reference line; the blade edge of the cutter projects outwards from the second axis; a blade body portion is formed in a spiral shape to extend continuously from the blade edge along the second axis; the cutter supporting portion includes a holder for supporting a proximal end portion of the cutter, and an intermediate supporting portion for supporting the blade edge at an intermediate position of the cutter relative to a longitudinal direction thereof to maintain the cutter in the posture slanted relative to the reference plane; and the intermediate supporting portion supports the blade body via a support ring.

2. The crown gear manufacturing device according to claim 1, wherein a scoop angle is set to render the blade edge to a posture where the blade edge progressively projects or recedes in the direction along the second axis as the blade edge moves away from the second axis.

3. The crown gear manufacturing device according to claim 1, wherein an oil supplying hole for supplying oil to the blade edge is formed along the second axis.

4. The crown gear manufacturing device according to claim 1, wherein the cutter supporting portion includes a posture changing mechanism for changing the posture of the cutter about a pivot axis parallel with the first axis; and the posture changing mechanism changes the posture of the second axis in correspondence with a tooth shape of a crown gear to be manufactured when the cutter is moved along the reference line by the moving portion.

5. The crown gear manufacturing device according to claim 1, wherein the moving portion moves the cutter supporting portion back and forth along a guide rail.

6. The crown gear manufacturing device according to claim 1, wherein the blade edge of the cutter is set with a scoop angle having a slant angle relative to the reference plane under a posture perpendicular to the rotational axis of this cutter.

7. The crown gear manufacturing device according to claim 4, wherein the blade edge of the cutter passes a contact point contacting the work and the cutter is pivoted about a pivot axis parallel with the first axis.

8. The crown gear manufacturing device according to claim 4, wherein while the moving portion is feeding the cutter toward the center of the work, the posture changing mechanism pivots the cutter about the pivot axis so as to constantly maintain a tooth trace formed in the work and the second axis at a fixed angle as viewed in the direction along the first axis.

9. A method for manufacturing a crown gear comprising the steps of: supporting a work rotatably about a first axis; supporting a cutter by a cutter supporting portion to be rotatably about a second axis different from the first axis; disposing the work and the cutter with disposing the second axis under a set posture along a reference line passing through the first axis and at an offset region offset from the reference line as viewed along a direction parallel with the first axis and disposing the second axis under a posture slanted relative to a reference plane extending perpendicular to the first axis, whereby the work and the cutter are configured to cause a leading end of the cutter to contact with the work at the offset region at an angle relative to a rotational plane of the work, wherein the cutter has a blade edge at the leading end of the cutter projecting outwards from the second axis; a blade body portion is formed in a spiral shape to extend continuously from the blade edge along the second axis; the cutter supporting portion includes a holder for supporting a proximal end portion of the cutter, and an intermediate supporting portion for supporting the blade edge at an intermediate position of the cutter relative to a longitudinal direction thereof to maintain the cutter in the posture slanted relative to the reference plane; and the intermediate supporting portion supports the blade body via a support ring; rotating the work and the cutter in synchronism in such a manner to move an outer circumference of the blade edge in a direction same as a rotational direction of the work; and moving the cutter parallel with the reference line, whereby the work is cut by the cutter.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a view showing a construction of a device for manufacturing a crown gear,

(2) FIG. 2 is a side view showing positions of a work and a cutter in the crown gear manufacturing device,

(3) FIG. 3 is a side view showing positions of the work and the cutter in the crown gear manufacturing device,

(4) FIG. 4 is a perspective view showing a leading end portion of the cutter,

(5) FIG. 5 is a side view showing the leading end portion of the cutter,

(6) FIG. 6 is a side view showing a supporting arrangement of the cutter according to a further embodiment (a),

(7) FIG. 7 is a side view showing a scoop angle of a blade edge of the cutter according to a further embodiment (b),

(8) FIG. 8 is a side view showing a scoop angle of a blade edge of the cutter according to a further embodiment (c),

(9) FIG. 9 is a side view showing a posture changing mechanism according to a further embodiment (e),

(10) FIG. 10 is a plan view showing a pivoting mode of the cutter according to the further embodiment (e), and

(11) FIG. 11 is a plane view showing the pivoting mode of the cutter according to the further embodiment (e).

MODES OF EMBODYING THE INVENTION

(12) Next, modes of embodying the present invention will be explained with reference to the accompanying drawings.

(13) [General Construction]

(14) As shown in FIGS. 1-3, a crown gear manufacturing device includes a work supporting portion 10 for supporting a work 1 to be manufactured rotatably about a vertically oriented first axis P1, a cutter supporting portion 20 for supporting a cutter 5 rotatably about a second axis P2 different from the first axis P1, a moving portion 30 for moving the cutter supporting portion 20 relative to the work supporting portion 10, and a synchronized driving portion 40 for driving the work supporting portion 10 and the cutter supporting portion 20 in synchronism with each other by applying driving forces thereto.

(15) The language crown gear herein is a generic name of gears having crown shape with teeth formed to extend perpendicular to a rotational axis, being inclusive of phase gears, a well as helical gears having a straight gear trace direction or a slanted gear trace direction. In particular, a crown gear of the invention will be effective for use as a high speed-reducing phase gear employed in a speed reducing system having a speed reducing ratio of 3 or more. In such high speed-reducing gear, its meshing-partner gear is formed as a small gear or a worm gear. Incidentally, of crown gears, those meshed with a pinion gear, a worm gear, etc. in a positional relationship offset from the axis are sometimes called crown gears, whereas those meshed with a pinion gear, a worm gear, etc. in a positional relationship perpendicular to the axis are sometimes called phase gears. However, in the context of the present invention, the language crown gear is understood as a concept inclusive of phase gears. And, with the inventive device for manufacturing a crown gear, it is possible to manufacture not only a crown gear, but also a phase gear.

(16) Further, with the inventive crown gear manufacturing device, in addition to the crown gear (or helical gear), a phase gear with two axes extending perpendicular to each other, as well as phase gears having two axes being offset from each other, can also be manufactured. Especially, among the phase gears, with the high speed-reducing phase gear having a speed reducing ratio of 3 or more, it is required to keep the number of teeth of the cutter small. Therefore, the present invention will be useful especially therefor.

(17) The second axis P2 is set under a parallel posture (an example of set posture) along a reference line L passing through the first axis P1 and extending radially as viewed in the direction along the first axis P1 and at an offset region offset by a set distance D from the reference line L. And, the second axis P2 is slanted by a slant angle relative to a reference plane S oriented perpendicularly to the first axis P1. The moving portion 30 has a moving direction which is set so as to move the cutter 5 linearly along a moving direction parallel with the reference line L.

(18) That is, the cutter 5, when at a position way from the reference line L by the set distance D in the offset region, is slanted in a virtual plane T oriented parallel with the first axis P1 and the reference line L.

(19) The synchronized driving portion 40 drives the work 1 and the cutter 5 in synchronism with each other so as to move an outer circumference of a blade edge 5A at the leading end of the cutter 5 toward the same direction as the moving direction of the work 1 at the same speed as the moving speed by rotation of this work 1, and the cutter 5 is moved in a direction parallel with the reference line L. With this, cutting is effected by skiving utilizing skidding occurring between the work 1 and the cutter 5 (skiving tooth cutting).

(20) [Specific Configuration of Device]

(21) The work supporting portion 10 includes a turn table 11 supported via a bearing to be rotatable about the vertically oriented first axis P1 and a plurality of chucks 12 for fixing the work 1 relative to this turn table 11; and the work supporting portion 10 is provided with a first electric motor M1 for driving/turning the turn table 11 about the first axis P1.

(22) The cutter supporting portion 20 includes a holder 21 for holding a base end portion of the cutter 5, a spindle 22 for transmitting a rotational drive force to this holder 21, and a supporting block 23 for supporting the spindle 22 rotatably about the second axis P2. This cutter supporting portion 20 is provided with a second electric motor M2 for rotatably driving the spindle 22. The supporting block 23 and the second electric motor M2 are supported to a movable frame 24.

(23) The movable frame 24 is supported to be movable relative to a guide rail 31 oriented parallel with the reference line L1; and the moving portion 30 includes a screw type moving mechanism 32 for moving the movable frame 24 back and forth along the guide rail 31 and a third electric motor M3 for driving this moving mechanism 32.

(24) The first electric motor M1, the second electric motor M2 and the third electric motor M3 respectively employ synchronous motors capable of control of rotational speeds thereof by driving signals. The synchronized driving portion 40 includes a synchronization control unit 41 having a microprocessor, a DSP or the like for controlling the first electric motor M1, the second electric motor M2 and the third electric motor M3, a means for acquiring work data so as to provide this synchronization control unit 41 with the working data, and a work data unit 42 having e.g. a storage for storing the work data.

(25) Incidentally, in FIG. 1, the crown gear manufacturing device is shown schematically so as to show its characterizing features for realizing the inventive arrangements thereof. This manufacturing device can be configured to include the cutter supporting portion 20 at a leading end of a manipulator. In such device having a manipulator as described above, a portion thereof having a mechanism for moving the cutter 5 will constitute the moving portion 30 in the context of the present invention.

(26) [Cutter]

(27) The cutter shown in FIG. 4 and FIG. 5 is an example having 2 (two) teeth. In this case, the cutter 5 is provided in the form of a bar extending along a rotational axis X which is set coaxial with the second axis P2 and forms, at the leading end thereof, a pair of blade edges 5A extending from the rotational axis and a blade body portion 5B extends in a spiral form from the blade edges 5A. The leading end of the cutter 5 as viewed in the direction along the rotational axis X is gourd-shaped, with the blade edges 5A being formed at outer circumference portion and an oil supplying hole 5C being defined along the rotational axis X. This cutter 5 is formed by shaping a round bar member formed of tool steel or super-hard alloy such as WCCo type, etc., and its cross sectional shape formed when cut in the direction perpendicular to the rotational axis X is in agreement with the gourd-shape at the leading end.

(28) Teeth of a crown gear are cut by a cutting operation with setting the cutter 5 to a posture slanted by a slant angle relative to the reference plane S. Therefore, the pair of blade edges 5A are formed with a shape which copies the shape of the tooth from its tooth bottom to the tooth crest. With this, in association with a cutting operation by rotation of the cutter 5, teeth and tooth grooves will be formed continuously in the work 1 along the circumferential direction.

(29) Further, when the cutting operation is effected with keeping the blade edges 5A in contact with the work 1, a working reaction force is applied from the work 1 to the cutter 5. Such working reaction force will cause a bending deformation in the cutter 5. However, in the instant embodiment, as the second axis P2 of the cutter 5 is slanted relative to the reference plane S, the working reaction force will be divided into a component force in the direction along the second axis S2 and a further component force in the direction perpendicular to the second axis P1, relative to the cutter 5. Of these component forces, the component force in the direction perpendicular to the second axis P1 which tends to bend the cutter 5 is smaller than the original working reaction force. Thus, the tendency to bend the cutter 5 too is reduced. Accordingly, positional displacement of the blade edges of the cutter 5 will less likely occur, so that the precise tooth shape can be formed in the work.

(30) As the cutter 5 of this embodiment comes into contact with the work under the slanted posture, a clearance angle is formed naturally between the plane of the work and the outer circumferential face of the cutter 5. Therefore, there is no need to provide any special clearance face in the cutter 5, so that the configuration of the cutter 5 can be simplified.

(31) Further, as only the spiral-shaped teeth need to be formed in the surface of the cutter and there is no need to form a plurality of teeth intermittently like a blade of a hob cutter. Hence, the cutter configuration can be simple.

(32) Since the blade shape of the cutter is adapted for the tooth shape of a crown gear to be formed, there is no need for re-cutting of teeth faces of the crown cutter after cutting.

(33) [Mode of Cutting]

(34) As shown in FIG. 1 and FIG. 2, when a crown gear is to be manufactured, a ring-shaped work 1 corresponding to the shape of the crown gear is supported to the turn table 11 of the work supporting portion 10 and the cutter 5 is supported to the cutter supporting portion 20. The work 1, when made of a metal material, can be a work prior to hardening, a work after hardening or a work after a working such as rough cutting. And, this work 1 is fixed to the turn table 11 by the chucks 12.

(35) With the above-described setting, the second axis P2 is set under the set posture along the reference line L passing through the first axis P1 and extending radially as viewed in the direction along the first axis P1 and at the offset region offset from the reference line L. And, the second axis P2 is slanted relative to the reference plane S oriented perpendicularly to the first axis P1 and the blade edges 5A of the cutter 5 are disposed at a position where they can come into contact with the rotational plane of the work 1 at the slant angle.

(36) Under the above-described condition, as the synchronization control unit 41 of the synchronized driving portion 40 controls the first electric motor M1 and the second electric motor M2 based on work data stored in the work data unit 42, a synchronized driving is effected for rotating the work 1 in a first direction R1 and rotating the cutter 5 in a second direction R2 at set speeds. During this synchronized driving, the synchronized driving portion 40 drives the third electric motor M3 to move the cutter 5, whereby the blade edges 5A of the cutter 5 are brought into contact the work 1 at the offset region, thus starting a cutting operation.

(37) As shown in FIG. 2, in the synchronized driving of the work 1 and the cutter 5, control is effected for moving the outer circumference of the blade edges 5A at the leading end of the cutter 5 in the same direction as the moving direction of the work 1 at the same speed as the rotational moving direction of the work 1.

(38) With this synchronized driving, the work 1 and the blade edges 5A of the cutter 5 come into contact at the same speed. However, as the blade edges 5A of the cutter 5 are placed in contact with the work 1 at the offset region, skidding occurs between the work 1 and the blade edges 5A. More particularly, in association with rotation of the work 1 along the first direction R1, the surface of the work 1 at the contacting position will move along an arc about the first axis P1; whereas, the blade edges 5A of the cutter 5 as being rotated about the second axis P2 move on the surface of the work 1 along the reference plane S and in the direction perpendicular to the reference line L. With this, between the work 1 and the blade edges 5A, skidding occurs in the radial direction about the first axis P1. And, the relative movement provided by this skidding, a cutting by skiving is realized.

(39) Incidentally, if the second axis P2 were disposed to be overlapped with the reference line L as seen in the plan view, the contact points of the work 1 and the blade edges 5A would both move in the circumferential direction about the first axis P1. So, almost no skidding would occur between the work 1 and the blade edges 5A; hence, cutting would be not possible.

(40) As described hereinbefore, since the pair of blade edges 5A are formed with a shape which copies the shape of the tooth of the crown gear, with the cutting operation, teeth of the crown gear will be formed in the work 1.

(41) As shown in FIG. 4, at the center of the cutter 5, the oil supplying hole 5C can be formed for supplying oil to the blade edges 5A during cutting.

(42) In this case, resistance associated with cutting can be reduced. Further, as heat generated during the cutting operation is removed, the property of the work 1 will hardly change, whereby damage of the cutter 5 can be avoided also. Moreover, cutting chips produced from the cutting operation can be discharged effectively by the flow of oil.

(43) [Function/Effect of Embodiment]

(44) As described above, in the instant embodiment, by disposing the cutter 5 driven to rotate about the second axis P1 relative to the offset region of the work 1 which is driven to rotate about the first axis P1, skidding is produced, thus realizing cutting. And, during this cutting, a crown gear can be manufactured with high efficiency by rotating the work 1 and the cutter 5 at high speeds.

(45) Further, as the cutting operation is effected only with the blade edges 5A portions at the leading end of the cutter 5 with slanting the second axis P2 relative to the reference plane S, in comparison with e.g. an arrangement of setting the second axis P2 parallel with the reference line L, it becomes easier to copy the shape of tooth formed in the work 1 to the shape of the blade edge 5A, and the manufacture of the cutter 5 too becomes easier.

(46) And, at the time of cutting, the force effective in the bending direction of the cutter 5 is reduced and also with supply of oil to the oil supplying hole 5C of the cutter 5 during cutting, deformation due to the effect of heat is restricted and discharging of cutting chips is made easier.

Other Embodiments

(47) In addition to the above-described embodiment, the present invention can alternatively be embodied as follows.

(48) (a) As shown in FIG. 6, a support ring 26 is provided as an intermediate supporting portion for externally engaging and loosely rotatably supporting the cutter 5 at an intermediate position thereof in the direction of the rotational axis X, and this support ring 26 is supported to the movable frame 24 of the cutter supporting portion 20. By supporting the cutter 5 at its intermediate position by the support ring 26, bending deformation of the cutter 5 during a cutting operation is restricted, so that the manufacturing precision of the crown gear can be enhanced.

(49) (b) As shown in FIG. 7, in the blade edge 5A of the cutter 5, a positive scoop angle can be set. This scoop angle is an angle representing the slant in the projecting direction of the blade edge 5A relative to the reference plane oriented perpendicular to the rotational axis X. With this setting of scoop angle, a cutting operation with sharp scooping can be effected during cutting, so that efficient cutting will be realized.

(50) (c) On the other hand, as shown in FIG. 8, in the blade edge 5A of the cutter 5, a negative scoop angle can be set. This scoop angle is an angle representing the slant in the receding direction of the blade edge 5A relative to the reference plane oriented perpendicular to the rotational axis X. With this setting of scoop angle, the resistance experienced by the blade edges 5A of the cutter 5 when coming into contact with the work 1 is increased. However, the cut surface of the work 1 will be smoother and excessive biting of the blade edges 5A of the cutter 1 into the work 1 will be prevented. So that, the rotational condition of the cutter 5 will be maintained appropriate, and in correspondence with the increase in the scoop angle, the service life of the cutter 5 will be improved also.

(51) (d) The cutter 5 can be configured such that the blade edges 5A of the cutter 5 are formed at three or more portions radially from the rotational axis X and the blade body 5B extends continuously helically from these three or more blade edges 5A. By forming the blade edges 5A at three or more portions as described above, through reduction in the rotational speed of the cutter 5 during cutting, frictional wear of the blade portions 5A of the cutter 5 can be realized.

(52) (e) As shown in FIG. 9, the crown gear manufacturing device can be alternatively configured as follows. Namely, in this, the cutter supporting portion 20 is supported to a posture changing mechanism 50 which is configured to pivot the cutter 5 about a pivot axis Q which extends through the contact point of the blade edge 5A of the cutter 5 with the work 1 and which extends parallel with the first axis P1, and the posture changing mechanism 50 is supported to the moving portion 30. The posture changing mechanism 50 includes a movable unit 51 movably supported to the guide rail 31, and a coupling unit 52 operably coupled with the movable unit 24. The movable unit 51 and the coupling unit 52 are connected to each other to be pivotable about the pivot axis Q and have their pivotal posture set by a fourth electric motor M4. With this arrangement, it is possible to pivot the posture of the second axis P2 with the range of set posture along the reference line L, as viewed in the direction along the first axis P1.

(53) In this further embodiment (e), the arrangement of disposing the blade edges 5A of the cutter 5 at the offset region and slanting the second axis P2 by the slant angle relative to the reference plane S is maintained. And, under the initial condition of cutting the outer circumference of the work 1 as viewed in the direction along the first axis P1, as shown in FIG. 10, the posture of the second axis P2 is set to a posture parallel with the reference line L. Thereafter, as approaching the first axis P1 of the work 1, the cutter 5 will be pivoted about the pivot axis Q by the posture changing mechanism 50. In this ways, while the cutter 5 is being fed toward the center of the work 1, the second axis P2 of the cutter 5 will be pivoted about the pivot axis Q extending parallel with the first axis P1 of the work 1, thereby to constantly maintain the tooth trace formed in the work 1 and the second axis P2 to a fixed angle. With this, it becomes possible to obtain a tooth shape having a same cross sectional shape at all positions from the outer circumference side to the inner circumference side of the work 1.

(54) Incidentally, the arrangement of this further embodiment (e), the cutter supporting portion 20 can be provided at a leading end of a manipulator. And, any arrangement can be used as long as it allows pivoting of the cutter 5 about the pivot axis Q.

INDUSTRIAL APPLICABILITY

(55) The present invention can be used as a device and a method for effecting a cutting work of a crown gear inclusive of phase gears, by skiving.

DESCRIPTION OF REFERENCE MARKS/NUMERALS

(56) 1 work 5 cutter 5A blade edge 5B blade body 5C oil supplying hole 10 work supporting portion 20 cutter supporting portion 30 moving portion 31 guide rail 40 synchronized driving portion 50 posture changing mechanism L reference line P1 first axis P2 second axis S reference plane X rotational axis scoop angle scoop angle Q pivot axis