High precision machining of ZC1 worm gear drives with large modulus. (November 2021)

• Record Type: Journal Article
• Authors: Deng, Xingqiao; Hong, Lei; Li, Wei; Wang, Shisong; Liu, Yucheng
• Is Part Of: Mechanism and machine theory. Volume 165(2021)
• Publication Date: 2021-11
• Subjects: ZC1 worm gear drive -- Principle of gear meshing -- Finite element analysis (FEA) -- Optimization of machining process; Machine theory -- Periodicals; Machinery -- Periodicals; Machines -- Périodiques; Génie mécanique -- Périodiques; Machine theory; Machinery; Periodicals; 621.81
• DOI: 10.1016/j.mechmachtheory.2021.104437
• Languages: English
• ISSNs: 0094-114X

Abstract

Highlights: Developed a set of space curve meshing equations for ZC1 worm drives based on the meshing theory. Presented an approach of employing five-axis machining to fabricate a worm pair. Developed an FE model for a ZC1 worm drive and investigated the contact behavior of the worm drive. Confirmed the machining efficiency and precision of the five-axis machining approach. Abstract: ZC1 worm drives are traditionally machined by grinding with grinding wheels. However, the process efficiency and machining precision of the grinding method are low and cannot meet the design requirements of worm/worm gear transmissions. In order to overcome those shortcomings, we propose a methodology of using five-axis machining to machine the ZC1 worm drives to attain higher efficiency and precision. A ZC1 worm gear drive model with was first created using MATLAB based on the gear meshing theory. Meshing analysis of the ZC1 worm drive was then performed using ANSYS to obtain equivalent stress and contact patterns under different operation conditions. Finally, ZC1 worm drives were machined via five-axis machining and grinding separately. The prototyped ZC1 worm drives were compared through experiments. Experimental data indicated that the distributions of surface wear and contact patterns of the five-axis machined worm drive are more uniform. Moreover, the application of the five-axis machining dramatically enhanced the machining efficiency and precision by significantly reducing the manufacturing time from 30 days to two days and minimizing the influence of human factor on the product properties.