Abstract: In order to obtain the precise tooth surfaces of worm-face gears, a new method of machining face gears was presented where the flying cutter machining method was used. The theoretical model of worm-face gears was established, the machining coordinate system was built based on the four-axis CNC boring machine，the machining mechanism of the proposed method was analyzed and divided into two stages: the imitation stage and the rolling cutting stage. The flying cutter machining method was used to solve the cutter trajectories, the cutting contact lines of the trajectories on the face gear blanks were obtained, which verifies the correctness of the proposed method. According to the two processing stages above, the relationship among cutter spindle speeds, workpiece axis speeds and feed speeds were solved. The machining programs were compiled and the simulation machining of worm-face gears was carried out in VERICUT, which verified the feasibility of proposed method. Finally, the machining experimental verification was carried out.

Key words: worm-face gear, flying cutter machining method, cutter trajectory, simulation machining

摘要： 为快速获取蜗杆面齿轮的精确齿面，提出了一种加工面齿轮的新方法——飞刀加工法。建立了蜗杆面齿轮的理论模型，基于四轴数控镗床建立加工坐标系，分析了所提方法的加工机理，并将其分为两个阶段：仿形阶段和分度加工阶段；采用飞刀加工法进行刀具轨迹的求解，得到了该轨迹在面齿轮齿坯上的切触迹线，验证了所提方法的正确性；求解了上述两个阶段中刀具主轴转速、工件轴转速及刀具进给速度之间的关系，编制了加工程序，并在VERICUT中对蜗杆面齿轮进行了仿真加工，验证了所提方法的可行性；最后进行了加工实验验证。

关键词: 蜗杆面齿轮, 飞刀加工法, 刀具轨迹, 仿真加工