Sub Micro
The manufacture of micro
Present, the drive motor, the rotor has been able to create a diameter of 0.5mm, outside diameter of a few millimeters of the micro-motor. However, because of this high-speed micro-motor, torque is small, to its full performance, you need the motor and load (actuator) joined the drive ratio between hundreds of micro-reducer. In a variety of transmission, the gear transmission is the most commonly used. Therefore, if reducer miniaturization, the need for miniaturization of the gear. ?
The following manufacturing method of micro-gear, small gear Ogasawara Corporation and its related cutting tools machining technique have been introduced. ?
Micro gear manufacturing method 1. Hob hobbing process? Usually hob in gear hobbing machine on the cutting system. Micro gear (m0.1 below) hobbing, the hob tooth must be micro-machining. Because small tooth, in addition to hob tooth profile error, the hob aperture beat, end beat, pitch and other error of micro gear will greatly affect accuracy. The processing of the hobbing machine, the workpiece spindle, tool spindle, the workpiece sub-degree institutions and Fixtures, and many other aspects of accuracy, stiffness and hob and the workpiece mounting accuracy, etc., will affect the manufacture of precision micro-gears, so it is necessary to improve accuracy of the total integrated manufacturing system. On this basis, then select the cutting of the material, you can more easily achieve the same volume modulus, the variety of different micro-gear. ?
2. Injection molding plastic gears? Use of plastic injection molding method for processing gear, due to mass production can be achieved in a short time, so much for office machines, home appliances and other gear used in light load. In recent years, rising in the injection molding technology, plastic material properties are improved, the precision injection molding gears with substantial increases in the precision plastic injection molds for the gears and injection molding technology are affecting an important factor in injection molding method. In the production of mold, the main use of wire cutting and EDM. However, as the use of wire, forming electrode discharge gap and other factors limit the improvement of micro-precision gear molds. Electroforming mold also can be used to manufacture. The base used for electroforming gear, using cutting or grinding can improve its accuracy. Pieces of gear can be plated thicker base. By chemical dissolution, by the sun (or convex) of the baseline conditions are overcast (concave) mold. Baseline conditions due to high precision gears, plating will not produce distortion and other reasons, it is possible to produce high precision micro-gear mold. As a result of baseline conditions, using chemical solution method, can be processed out of the mold to the shape of complex, in addition to spur gears, helical gears, the bevel gears, face gears, worm and other types of mold can be manufactured. Using high-precision molds, so that mass production of plastic micro-gear possible. However, the gear is small, easily deformed by the force and other reasons, the large load transmission and drive high precision of the occasion, with great strength of the metal gear is more favorable. ?
3. Sintered metal production method? Metal powder in the mold after molding, high pressure, high temperature sintering is made of sintered metal gears curing (powder metallurgy gear), its high mechanical strength than the plastic gears in the middle-load conditions of use. Molding method suitable for mass production. But the die forming, after a high temperature sintering, large deformation, so to achieve the necessary precision, but also in the sintered gear for finishing. As the tooth small, micro gear finishing difficult, combined with a larger metal particles of metal powder, thus limiting the shape precision and surface finish improvement. If mold injection molding plastic gears used in the above mentioned benchmarks Gear electrode electrochemical machining method, the accuracy of their processing out of gear is likely to increase. ?
4. Other manufacturing methods? Using semiconductor manufacturing method, optical or laser etching method can create micro-machining of gear. Optical loss method can trial out of hundreds of tiny micro-sized gears, broaches can be drawn inside the gear. Future demand for more and more micro-gear, new manufacturing methods and mass production technology will also continue. ?
Trial Production of Micro-gear Ogasawara Corporation hob with the company’s existing cutting techniques to achieve the smallest possible number of micro-gear of the trial mode. ?
Use the hob main parameters: modulus m: 0.01, pressure angle : 20 °, tooth groove: 12, OD OD: 25mm, inner hole diameter: 10mm, Hob Width: 8mm, Material: hard quality alloy. ?
Hob Accuracy: Class 3A according to the company hob precision manufacturing. Zeiss universal microscope (UMM200) measurement gear; end jitter will use the company’s radio micrometer ESM-01 measurements.
Trial production of micro gear main parameters: modulus m: 0.01, pressure angle : 20 °, tooth type: involute, number of teeth Z: 100, OD OD: 1.02mm, Material: BS.
Exposure meter can not measure gear m0.3 below gear, so at 200 times the projector used to enlarge map to test the accuracy of the measurement method of tooth up to 2 ~ 3 m. Hob and transformation using precision high precision gear hobbing machine, hob and the workpiece can be installed within 1 m precision control. On the manufacture of micro-gears, and the results show that the hobbing can be used to manufacture high-precision micro-gear. ?
To further study the practical value of micro-gear, were micro-loss measurement meshing gears. The results show that the appropriate lubrication mode, the results and the general size of the gear at the same level.
Miniature tooth face gear reducer end trial
Micro gear meshing efficiency measurement, confirmed the possibility of its practical, then use of micro-end gear and pinion planetary gear reducer trial of the variation. As the miniaturization of precision machine parts after the relative variation, and therefore to the development of precision micro-reducer of the bodies is not sensitive. To this end, reducer various parts of the axial position will be based on gear mesh adjustment condition of the site. Trial of the reducer using the axial position adjustment achieved without backlash drive.
Trial gear reducer used parameters are as follows: m: 0.05, : 20 °, Z1: 100, Z2: 21, Z3: 102, Z4: 100 (Z1, Z3, Z4 is a face gear, Z2 is a small gear), outer diameter: 6.6mm, length: 7.4mm, reduction ratio of about 1:101, transmission torque, reduction ratio and the total power of the relationship is as following:
Input torque: i = 1
Output torque: o = ( 1 2Z4/Z1 + 2 3Z4/Z3) / (1- 2 3Z4
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