Kamchatna-Stepanova K. Improving the efficiency of mechanical processing of hardened large-module chevron wheels during high-speed gear milling

The thesis is devoted to the development of processes for improving the efficiency of mechanical processing of hardened large-module chevron wheels with special cutters during high-speed gear milling, which is an urgent task of modern mechanical engineering. The scheme of the cutting process with worm cutters with a separate shaping scheme due to the contact field of the cutter cutting is investigated and implemented. A geometric model of the kinematics of the process of processing teeth with a worm cutter is developed with the differentiation of the cutting work by each of its teeth in the contact field of cutting and the nature of the cutting of the teeth of the cutter into the metal of the 24 workpiece is clarified. The analysis of the process of cutting teeth is considered as the trajectory of movement of any point of the cutting edge of each of them in the kinematics of mutual movements of the tool and the workpiece. The influence of the trajectories of the cutting edges of the milling cutter teeth on the thickness of the cut layer, the wear of the milling cutter, on the undulation and roughness of the treated surface of the wheel teeth is studied. A mathematical model has also been developed for calculating the efficiency of milling cutters with a separate shaping scheme in the range of the number of teeth z = 30-90, where, with a much smaller profile angle of the teeth than for standard milling cutters, the calculated wave height is 2.5 times less, which indicates the possibility of a significant increase in the tool feed. A mathematical model has been developed for calculating systematic profiling errors and the accuracy of processing Archimedean chevron teeth with worm cutters due to a comparative theoretical analysis of organic profiling errors of large-module worm cutters with a standard profile angle of the original contour of the tool rail and special worm cutters with a separate shaping scheme with a reduced profile angle of the original contour. A method for conducting experimental studies of the cutting properties of worm cutters with a separate shaping scheme has been developed. Practical recommendations for use have been developed.