多因素耦合剃齿齿形"中凹"误差机理与剃齿刀修形曲线研究

Gear shaving "mid-concave" is the main factor of gear vibration and noise as well as useful life shortening. However, due to the complexity of the formation mechanism and influence factors, it's quite difficult to reveal essential character of tooth profile "mid-concave" error. The object of the project is to theoretically and experimentally investigate the formation mechanism and influence factors of tooth profile "mid-concave" error. Based on the basic meshing principle of three-dimensional staggered shaft spiral gear, the three-dimensional parametric models for the shaving cutter and the work gear are respectively established to study the influence factors of tooth profile "mid-concave" error. The test platform is built to illustrate the formation mechanism of tooth profile "mid-concave" error. According to the sensitivity theory and model modification method, the gear tooth surface models considering the single or multi-coupling factors of the tooth profile "mid-concave" error is established, and the modification curve of the shaving cutter is obtained. The gear tooth surface models are solved based on the optimization theory and the nonlinear solution strategy, and the validity and rationality of modification curve are verified by the integrated experiment platform. Based on the combined method including theory analysis and experiment validation, we can explore the formation mechanism and basic rules of tooth profile "mid-concave" error; form a suit of theoretical methods of shaving cutter and offer theory and methodology to quantification research of tooth profile "mid-concave" error. The project has emphasis theoretic and practical significance to improving stationary and useful life of gear transmission.

剃齿齿形"中凹"误差是影响齿轮传动平稳、承载能力和使用寿命的主要原因，由于剃齿过程齿形"中凹"误差的形成机理与影响因素极为复杂，难以定量分析以揭示其本质特征。项目拟以交错轴螺旋齿轮的基本啮合原理建立剃齿刀与工件齿轮齿面模型入手，分析产生齿形"中凹"误差的主要因素，通过构建基础实验平台揭示齿形"中凹"误差的形成机理；利用灵敏度理论与模型修正方法，建立单因素和耦合多因素影响齿形"中凹"误差的齿面模型；根据优化理论和非线性求解策略对所建立的齿面模型求解，通过映射关系获得正确的剃齿刀修形曲线，并通过搭建综合实验平台验证修形曲线的正确性。项目通过实验、机理探索、建模、求解、验证、模型修正、再求解、再验证的思路，揭示齿形"中凹"误差形成的内在机理及其规律，形成剃齿刀高效修形技术方法，为齿形"中凹"误差问题的定量化研究及剃齿刀正确修形提供理论和方法支持，对实现剃齿高效加工具有重要的理论与实际指导意义。

剃齿齿形“中凹”误差是影响齿轮传动平稳、承载能力和使用寿命的主要原因，由于剃齿齿形“中凹”误差的形成机理与影响因素极为复杂，目前仍是剃齿加工工艺的关键难题。. 项目研究以交错轴螺旋齿轮的基本啮合原理为基础，建立了剃齿刀与工件齿轮的齿面模型，真实地反映了剃齿加工过程；提出了剃齿加工特性（接触特性和传动特性）作为中间变量来研究剃齿齿形“中凹”误差机理的研究方法，建立了单因素影响剃齿齿形“中凹”误差模型，揭示了重合度、接触变形与剃削力、剃削速度和主轴转速、径向进给速度和轴向进给速度等主要因素影响剃齿齿形“中凹”误差的机理及其规律；探索了在易发生剃齿齿形“中凹”误差的重合度范围内，考虑剃削力、剃削速度等多因素的剃齿齿形“中凹”误差模型的建模与求解，并通过实验验证了模型的正确性；提出的剃齿刀优化设计基本方法，为进一步消除和减少剃齿齿形“中凹”误差奠定了基础；提出的基于剃齿刀与工件齿轮啮合点数变化获取剃齿刀修形曲线的方法和基于剃齿啮合接触分析获取剃齿刀修形曲线的方法，应用于生产取得了消除和减少剃齿齿形“中凹”误差良好的工艺效果，提出的非等边剃齿刀的设计思想，为消除和减少剃齿齿形“中凹”误差提供了新的技术思路。. 项目研究成果发表在《机械工程学报》、《振动与冲击》等重要学术期刊上，发表SCI/EI期刊论文14篇，CSCD核心期刊论文4 篇，中文核心期刊论文3 篇；授权发明专利4项、实用新型专利5项，受理发明专利11项。这些研究成果为剃齿齿形“中凹”误差问题的定量化研究及剃齿刀正确修形提供了科学的理论和技术方法支持，为消除和减少剃齿齿形“中凹”误差提供了有效的解决途径，对实现剃齿高效加工具有重要的理论与实际指导意义。