Lead template
A commonly used lead calibration template is a spiral surface shape machined on a steel cylindrical body. Even if such a model is manufactured and evaluated using an ultra-high-precision method, the evaluation of the shape accuracy of the three-dimensional spiral surface still contains considerable uncertainty. Figure 6 is a schematic diagram of the newly designed lead reference template to solve this problem. An ellipse whose short diameter is equal to the pitch circle diameter is very close to the helix to be detected in three dimensions, so the ellipse can be used as a lead reference. The shape of the template is wedge-shaped, and the wedge angle of the template is a function of the helix angle, the diameter of the base circle, and the radius of the probe tip, which needs to be properly selected. When measuring the lead error, even if the probe is driven by a spiral, the probe tip moves along an elliptical path on a tangent plane of the pitch cylinder. The vertical deviation between the spiral and the ellipse forms an index S curve, which is The function of the template corner (as shown in Figure 7). During the measurement, the amplitude of the deviation is within the range of the sensor output that ensures accuracy over the range of available angles of rotation. This deviation can be obtained mathematically and can be used as a reference reference for the lead calibration, just as the TCB curve is used for tooth profile calibration. The difference between the measured curve and the theoretical curve is again used here as a deviation curve for evaluation.
Figure 7 Measurement example of the lead detector
Figure 8 Ball-wedge template for involute and lead detector calibration
Wedge templates can take different forms: one form contains a complete ellipse; the other form is an arc length containing only ellipse, which is usually not a chamfered cylinder, but a polyhedron-like form, suitable for large Lead reference template for diameter gears.
Ball-wedge template
We can manufacture spherical and wedge-shaped templates very accurately, and we can also evaluate their three-dimensional shape accuracy (within 50 nanometers accuracy) very accurately. Due to the high precision, the result of the calibration means that the item or position where the gear detector may be problematic can now be calibrated.
In the calibration process, there is a problem that causes uncertainty, that is, the measurement accuracy of the position state of the template mounted on the gear measuring instrument is not high enough. This problem can be solved well by a combined ball-wedge template (BWA). The structure of the BWA is to integrate the spherical template with the wedge template, as shown in FIG. By using the BWA template, when mathematically finding the cause of uncertainty affecting the accuracy of the detector, the number of unknowns of the mounting position of the template on the detector can be reduced, because during the measurement of the profile calibration and the lead calibration, The position of the BWA in the three-dimensional space on the detector does not change.
in conclusion
The template and calibration method recommended in this paper is only applicable to CNC gear measuring instruments. Most of the gear measuring instruments currently on the market are CNC type instruments. We are convinced that this calibration method is very effective, so we will determine this method as the future Japanese Industrial Standard (JIS), and we will also recommend this method as the ISO standard.
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