As we know, traditional turning machining involves a stationary tool and a rotating workpiece, while traditional milling machining is the opposite. What catches everyone’s attention in the video is that both the workpiece and the tool are rotating rapidly. Several industry experts pointed out that the rotation of the machine spindle and the tool needs to satisfy strict mathematical relationships, namely the speed ratio. This is precisely the key to rotary indexing machining technology. Now, let’s reveal its mystery.

什么是旋轉(zhuǎn)分度加工？

定義

旋轉(zhuǎn)分度加工，簡(jiǎn)稱(chēng)旋轉(zhuǎn)分度，是指刀具和工件同時(shí)旋轉(zhuǎn)，實(shí)現(xiàn)切削和分度的加工方法。通過(guò)調(diào)整它們之間的速比，可以加工不同類(lèi)型的零件。適用于加工表面呈圓形分布的零件，如齒輪、花鍵等。

機(jī)制

旋轉(zhuǎn)分度加工的重點(diǎn)是控制加工過(guò)程中每個(gè)瞬間工件與刀具之間的相對(duì)位置和運(yùn)動(dòng)，使接觸點(diǎn)的運(yùn)動(dòng)軌跡成為一條直線。這是利用數(shù)學(xué)中形成漸開(kāi)線的原理，因此也稱(chēng)為漸開(kāi)線加工。雖然聽(tīng)起來(lái)很簡(jiǎn)單，但它涉及復(fù)雜的數(shù)學(xué)函數(shù)。加工運(yùn)動(dòng)軌跡可以看作是兩個(gè)運(yùn)動(dòng)的合成：

1、繞基圓圓心O公轉(zhuǎn)，速度為np的圓周運(yùn)動(dòng)；

2.繞自身中心C旋轉(zhuǎn)的速度為nc的圓周運(yùn)動(dòng)。通過(guò)調(diào)整速比等參數(shù)，可以實(shí)現(xiàn)不同的加工路徑。詳細(xì)的數(shù)學(xué)計(jì)算這里就不解釋了。

旋轉(zhuǎn)分度加工的優(yōu)點(diǎn)和缺點(diǎn)

旋轉(zhuǎn)分度加工的主要優(yōu)點(diǎn)是將傳統(tǒng)的間歇加工轉(zhuǎn)變?yōu)殚g歇連續(xù)加工，節(jié)省分度時(shí)間，顯著提高加工效率，獲得更好的表面精度。另外，它屬于干式切削，不需要切削液，在一定程度上降低了生產(chǎn)成本，是一種經(jīng)濟(jì)的加工工藝。

然而，旋轉(zhuǎn)分度加工并不是一項(xiàng)完美的技術(shù)。當(dāng)加工不同尺寸的零件時(shí)，需要重新編程，增加了操作難度。刀具磨損也比傳統(tǒng)加工更嚴(yán)重。這些缺點(diǎn)限制了其實(shí)際應(yīng)用，目前僅用于小規(guī)模生產(chǎn)。

旋轉(zhuǎn)分度加工設(shè)備的開(kāi)發(fā)

海外

德國(guó)和日本是最早探索旋轉(zhuǎn)分度加工設(shè)備領(lǐng)域的國(guó)家。他們已經(jīng)開(kāi)發(fā)出相對(duì)成熟的技術(shù)并投入生產(chǎn)。

Germany can be considered a pioneer in the development of CNC rotary indexing machines. In the early days, they developed CNC rotary indexing cutting technology based on the needs of German car manufacturers such as Mercedes-Benz, patented it globally, and developed powerful CNC involute rotary indexing machining equipment. To this day, they are still committed to the research and development of dedicated cutting machines based on rotary indexing theory. One of the distinctive technologies of Germany’s Wera is the use of patented rotary indexing technology, combining hobbing and broaching in the method called “hob-broach.” It can machine various tooth profiles, including involute and non-involute, without the need for tool retraction grooves.

日本還開(kāi)發(fā)了旋轉(zhuǎn)分度機(jī)，可用于加工溝槽類(lèi)零件、齒輪倒角和去毛刺以及復(fù)雜表面。

國(guó)內(nèi)的

我國(guó)于2003年左右開(kāi)始研究旋轉(zhuǎn)分度加工，并取得了一些重要的研究成果。加工范圍包括R系列槽型（小軸、盤(pán)齒、軸齒）、M系列復(fù)雜曲面（方形、六角形、多邊形、組合齒）。我國(guó)高校從2002年開(kāi)始研發(fā)具有自主知識(shí)產(chǎn)權(quán)的旋轉(zhuǎn)分度加工技術(shù)和裝備，重點(diǎn)發(fā)展旋轉(zhuǎn)分度倒角加工中心。他們成功開(kāi)發(fā)了旋轉(zhuǎn)分度倒角加工中心，并完成了同步器齒套上凹槽和錐度倒角的加工。

However, due to factors such as strong specialization and operational difficulty, China’s CNC rotary indexing machines still have a significant gap, urgently requiring researchers to fill. Currently, most machine tools used by Chinese enterprises rely on imports, resulting in high costs.

結(jié)論

The advantage of rotary indexing machining lies in its high efficiency, reducing the machining time from minutes to tens of seconds. Although it has not been widely popularized due to current development constraints, it is still a highly promising new technology. With the joint efforts of researchers and enterprises, the future of rotary indexing machining is expected to create a new situation in China’s machining industry.