"四刀法"高效、低耗加工弧齿锥齿轮的理论和实验研究

In the recent years, "two cut method" for the tooth cutting of spiral bevel gear(including hypoid gear) with CNC gear milling machine imported from abroad has the problem of tool consumption, meanwhile the traditional "five cut method" is not efficient nor accurate enough. The new method, "four cut method", is proposed with the advantages of high efficiency and low cost, of which the foundational theories and key techonologies are studied. The reflctive relationships between cutting force and amount of cutting feed, as well as cutting speed and tool life of rough-machining in the gear forming process are researched, then the effects of the uniform cutting force on high cutting efficiency and low tool cost in the dry cutting process are discussed. The relationships amoung hobbing speed, cutting feed and tool load in the process of pinion rough machining are investigated, and the effection of modifying hobbing speed on improving cutting efficiency in rough machining of pinion is discussed. The machining theory of "duplex spread blade" for finishing cutting pinion is studied, and then the feature of "cut tool tilt and modifying-roll" is integrated into the process of spiral bevel gear finishing cutting. By establishing topological form of tooth surface, sensitivity matrix of the machining parameters and visual simulation system for tooth contact analysis, a brand new design of duplex spread blade for finishing cutting spiral gear is put forward theorically, namely reverse lean design. The project explores the unrevealed scientific problems for generating cutting of spiral bevel gear based on homebred CNC gear milling machines, particularly for application of the proposed "four cut method" in manufacturing, which will act as the technical spport for improving cutting efficiency and reducing tool cost.

针对近几年进口的数控铣齿机"两刀法"加工弧齿锥齿轮（包括准双曲面齿轮）存在刀具消耗大，而传统的"五刀法"又存在制齿效率低、精度差的问题，提出"四刀法"高效、低耗加工弧齿锥齿轮的新方法，并对其基础理论及关键技术展开研究。研究大轮成形法粗切中切削力与进给量、切削速度与刀具耐用度的映射关系，探讨干切加工中保持等切削力对降低刀具消耗、提高切齿效率的作用；研究小轮粗切加工中滚切速率与切削量、刀具受力之间的关系，探讨变滚切速率对提高小轮粗切效率的影响。针对小轮双面法精切加工理论展开研究，将"刀倾＋变性"应用于弧齿锥齿轮的精切加工中，通过构建齿面拓扑结构与加工参数的敏感性矩阵并建立齿面接触状况可视化仿真系统，提出全新的弧齿锥齿轮双面法精切加工设计理论-逆向精益设计方法。本项目基于国产数控铣齿机研究弧齿锥齿轮切齿加工尚未揭示的科学问题，为"四刀法"在生产中推广应用，为高效切齿并降低刀具消耗提供技术支撑。

针对近几年进口的数控铣齿机“两刀法”加工弧齿锥齿轮（包括准双曲面齿轮） 存在刀具消耗大，而传统的“五刀法”又存在制齿效率低、精度差的问题，提出“四刀法” 高效、低耗加工弧齿锥齿轮的新方法，并对其基础理论及关键技术进行了深入研究。.研究了大轮切削时切削力与切削参数的内在关系，提出切削力计算模型；建立基于切削力恒定的成形法变进给速度的优化模型；建立刀具、切削速度与单件加工时间的目标函数，优化切削参数，提高刀具寿命，切齿时间缩短了23.82%。.建立了滚切法高效粗加工弧齿锥齿轮小轮的数学模型，推导切削面积计算公式，完成瞬时切削力计算，研究铣削过程会中切削参数与刀具受力的关系，建立效率、成本的多目标函数，实现对切削参数的优化并有效提高了加工效率。.根据齿轮啮合原理，利用齿根倾斜技术完成弧齿锥齿轮都采用双面法加工的几何参数计算、加工参数设计。建立了弧齿锥齿轮大轮和小轮都采用双面法加工的数学模型，构建出数字化齿面，完成了原始齿面的构建；推出齿面误差计算方法，在此基础上研究了 “刀倾”、“变性运动”、“螺旋运动”对齿面拓扑结构的影响，分析各加工参数误差对齿面结构影响的权重，建立了加工参数对齿面拓扑结构的敏感性矩阵。.研究齿面失配与齿面接触区的对应关系，通过构建失配量实现对原始接触区的预控，由原始齿面和失配量建立目标齿面，通过敏感性矩阵和失配量得到目标齿面的加工参数修正量，形成大小轮都能双面切齿的精益设计方法，并通过切齿实验验证了上述理论的正确性。通过优化切削路径实现了在同一台机床上一次装夹完成弧齿锥齿轮小轮凸凹面的加工，摆脱了弧齿锥齿轮小轮双面法精切加工对进口高端机床和刀具的依赖。