What factors affect the selection of gear machining adjustment method for ZLY200-16-I reducer

ZLY200-16-I is a hard tooth helical gear reducer (center distance 200mm, transmission ratio 16, assembly type I). The selection of gear machining adjustment method needs to be comprehensively judged based on five core factors: gear accuracy requirements, production batch, equipment conditions, process chain, and working condition requirements. The specific impacts of each factor are as follows:

1. Requirements for gear accuracy level

The gear of this type of reducer usually needs to meet the accuracy level 6 of GB/T 10095. If the accuracy requirement is increased to level 5 (such as high-speed and low-noise working conditions), the CNC grinding closed-loop compensation adjustment method must be selected. Through in-situ measurement and real-time parameter correction, the tooth profile, tooth direction, and tooth pitch errors can be accurately controlled; If it is a non core transmission scenario, the accuracy requirement can be relaxed to level 7, and the gear hobbing adjustment method can be used (without the need for gear grinding process) to reduce processing costs. The precision requirement directly determines the technical threshold of the adjustment method, and the high-precision requirement corresponds to the adjustment scheme of high automation and closed-loop control.

2. Production batch and cost budget

When single piece trial production or small batch production (≤ 10 pieces) is limited by cost and efficiency, the trial cutting adjustment method can be used, relying on the experience of technical personnel to complete the processing through multiple trial cutting, testing, and correction. Although the cycle is long, there is no need to solidify the parameter library; When producing small to medium batches (10-50 pieces) or large batches (≥ 50 pieces), the CNC gear grinding closed-loop compensation adjustment method is preferred. It can solidify the grinding wheel dressing amount, worktable tilt angle, grinding parameters, etc., establish a standardized parameter library, ensure the consistency of gear accuracy in the same batch, and reduce the single piece rework rate, balancing cost and efficiency. When the cost budget is sufficient, in place measuring devices can be configured to further improve adjustment accuracy; When the budget is limited, a semi closed loop solution of offline detection and manual adjustment can be adopted.

3. Processing equipment and testing capabilities

The feasibility of the adjustment method is directly determined by the equipment configuration: if high-precision equipment such as CNC gear grinding machines (such as Qinchuan YK7232, Reishauer RZ301S), gear comprehensive inspection instruments, and coordinate measuring instruments are available, closed-loop compensation adjustment method can be implemented; If there are only ordinary gear hobbing machines and ordinary gear grinding machines without in-situ measurement function, then only trial cutting adjustment method or pitch circle adjustment method can be used, and the machine tool parameters can be manually corrected through manual detection data, resulting in poor accuracy consistency. Detection capability is the key support for the implementation of adjustment methods. Without high-precision detection instruments (such as tooth profile measuring instruments), even if closed-loop adjustment methods are used, accurate error data cannot be obtained, resulting in adjustment failure.