高速渐开线圆柱齿轮齿面设计及数控加工技术研究

发布时间：2018-06-08 16:59

  本文选题：渐开线圆柱齿轮 + 真实齿面　； 参考：《西北工业大学》2015年博士论文

【摘要】：针对舰船、航空齿轮箱中的直齿轮、斜齿轮及人字齿轮,以齿轮啮合理论、有限元方法为基础,围绕修形齿面建模、实际齿面的建模、几何啮合仿真、承载啮合仿真、应力过程仿真、不同应用场合齿轮的目标修形优化、多轴联动多自由度数控加工及高阶传动误差齿面设计展开,系统地进行理论和实验研究,总结出一套具有工程使用价值的齿面修形优化设计软件和方法,达到提高传动系统平稳性,降低振动噪声的目的,论文主要研究内容如下:(1)对齿轮承载接触分析模型进行完善,给出考虑基节误差的承载接触分析计算方法,结果表明:基节误差放大了承载传动误差幅值,引起较大振动及载荷分配的不均匀。对修形人字齿轮三维有限元进行精确齿面控制建模和装配,按照Abaqus有限元软件输入文件的编写规则进行批处理加载分析,并与承载接触分析方法的结果对比,表明了二者分析结果一致性,验证了本文承载接触分析方法的正确性与高效性。(2)建立基于齿面坐标测量的真实齿面模型,采用理论齿面叠加法向偏差曲面表达实际齿面,推导实际齿面接触过程,相对直接通过复杂曲面拟合的数字齿面,提高了计算效率和拟合精度。(3)提出的斜齿轮对角修形能够保证修形后齿面瞬时接触线长度不变,在减振降噪的同时,兼顾了齿轮的强度,三维拓扑修形真实反映齿面实际状况。齿面修形优化设计以承载接触分析为基础,从减振、降噪、提高强度为出发点,分别以承载传动误差幅值最小、啮合线相对振动最小、齿面闪温最小、齿面载荷均匀及多个目标进行修形优化设计。结果表明:齿廓修形后,轮齿接触区润滑状态改善,导致齿面闪温减小,直齿轮单齿啮合区内闪温变化不明显;人字齿轮的轴向窜动是左右齿面间隙相互补偿的过程,齿向修形与轴向窜动相互补充,保证了齿面载荷整体上均匀;随转速、载荷的增加,啮合冲击逐渐增大,且随转速增加,啮合冲击激励较刚度激励的振动更加明显,因此系统共振的敏感性降低,多载荷承载传动误差幅值反映了振动随载荷变化趋势;人字齿轮轴向位移激励对啮合线方向振动无影响,轴向位移激励是引起轴向、扭摆方向振动的主要原因;修形降低了啮合激励,因此,有效降低了系统振动。(4)根据空间齿轮啮合原理,建立修形齿面多轴、多自由度的多种数控加工模型。基于刀具廓形修形及机床各轴运动敏感性分析,通过优化齿面误差最小,得到刀具修形参数及机床各轴运动参数。结果表明:(1)根据齿廓修形齿面反算砂轮廓形,进行数控五轴联动成形磨削,可实现拓扑修形齿面的高精度加工;(2)平面砂轮磨齿时,沿齿向方向压力角、螺旋角、展成角附加运动可分别实现一定的对角修形加工,机床增加齿向运动,可减小平面砂轮半径,用于磨削大螺旋角、大齿宽对角修形斜齿轮;(3)当滚刀有齿向修形时,再增加合理的切向运动,使得滚切过程中,产生沿齿向方向齿形的连续变化,弥补了传统加工产生的齿形扭曲;修形滚刀齿形及增加切向运动可实现一定的拓扑修形齿面加工;(4)锥面砂轮沿轴向冲程运动时,通过等粗糙度磨齿法,确定砂轮每次冲程的径向位置及冲程总次数,与通用的匀速展成及径向均速展成磨齿法相比,可显著减小理论粗糙度值,该方法可磨削更为复杂的修形齿面;砂轮沿齿向冲程运动磨削对角修形斜齿轮时,冲程方向与接触线方向一致,根据展成原理求解工件附加运动,数控编程简单,其关键技术为啮入点的准确对刀,对角修形磨齿试验验证了该方法的正确性。(5)为了进一步降低轮齿振动,提出一种考虑展成磨齿加工的高阶传动误差齿面设计方法,通过优化承载传动误差幅值最小确定其曲线及加工参数;对比斜齿轮2阶、4阶及高阶传动误差齿面的承载传动误差表明:无修形齿轮由于重合度不变,随载荷增加承载传动误差幅值不断增加;修形后随载荷增加,齿面间隙逐渐减小,重合度不断增加,承载传动误差幅值逐渐降低,当齿面间隙完全消除后,重合度不再变化,随载荷的增加,承载传动误差幅值逐渐增大;对于高重合度齿轮副,高阶传动误差齿面更能有效降低承载传动误差幅值,因为其曲线自由度较高,更有利于降低多齿对啮合引起的重合度变化;通过修形齿面曲率分析,表明平面砂轮进行展成磨削高阶传动误差齿面是可行的,不存在干涉;除此之外,提出一种考虑接触印痕的内凹型高阶传动误差齿面,结果充分证明其更能有效降低轮齿承载传动误差幅值,其内凹程度受载荷大小影响。(6)齿面振动试验表明修形齿轮具有更好的动态性能,在设计载荷处,传动误差和振动幅值均能够下降30%或更多,验证了本项目的理论方法是可以用于工程实践的。
[Abstract]:The spur gear, helical gear and character gear in the gear box are based on the gear meshing theory and the finite element method. It is based on the gear meshing theory and the finite element method. The modeling of the tooth surface, the actual tooth surface modeling, the geometric meshing simulation, the bearing meshing simulation, the stress process simulation, the optimization of the target modification of the different application field gear, the multi axis multi freedom numerical control adding. The design of work and high order transmission error tooth surface design is carried out, the theoretical and experimental research is carried out systematically. A set of software and method for the optimization design of tooth surface modification with engineering value is summed up to improve the smoothness of the transmission system and reduce the vibration noise. The main contents of this paper are as follows: (1) the contact analysis model of gear bearing is carried out. The calculation method of bearing contact analysis considering the base error is given. The results show that the base error magnifies the amplitude of the bearing transmission error and causes the uneven distribution of the vibration and load. The modeling and assembly of the precise tooth surface control for the three-dimensional finite element of the modified human character gear is made according to the compiling of the Abaqus finite element software. Then, the batch loading analysis is carried out and compared with the results of the bearing contact analysis method. The results show the consistency of the two analysis results, and verify the correctness and efficiency of the contact analysis method in this paper. (2) a real tooth surface model based on the coordinate measurement of tooth surface is established, and the actual tooth surface is expressed by the superposition method of theory tooth surface to the deviation surface, and the actual tooth surface is expressed by the theory of theory tooth surface superposition. The contact process of the actual tooth surface can improve the calculation efficiency and the fitting precision relative to the digital tooth surface fitted directly by the complex surface. (3) the diagonal modification of the helical gear can ensure that the length of the instantaneous contact line of the tooth surface can be kept constant, while the strength of the gear wheel is taken into account while the vibration and noise reduction is reduced, and the three-dimensional topology modification truly reflects the actual tooth surface. The optimization design of tooth surface modification is based on the bearing contact analysis, starting from vibration damping, noise reduction and strength improvement, with the minimum amplitude of the transmission error, the smallest relative vibration of the meshing line, the minimum flash temperature of the tooth surface, the uniform load of the tooth surface and the optimization of multiple targets. The results show that the tooth contact area is lubricated after the tooth profile modification. The state improvement leads to the decrease of the temperature of the tooth surface, and the change of the flash temperature in the single tooth meshing area of the spur gear is not obvious; the axial movement of the human gear is the process of compensating the gap between the left and right teeth, and the tooth surface modification and the axial movement complement each other to ensure the uniform load on the tooth surface, and the meshing impact increases gradually with the speed and the load increasing, and with the speed of the gear, and with the speed of the gear. In addition, the vibration of the meshing impact excitation is more obvious than the stiffness excitation, so the sensitivity of the system resonance is reduced. The amplitude of the multi load bearing transmission error reflects the trend of the vibration with the load, and the axial displacement excitation of the human character gear has no influence on the direction of the meshing line, and the axial displacement excitation is the main source of the vibration of the axis and the direction of the torsion pendulum. Because the modification reduces the meshing excitation, therefore, it effectively reduces the vibration of the system. (4) based on the principle of space gear meshing, a variety of numerical control machining models of multi axis and multiple degrees of freedom are established. Based on the profile modification of the cutter and the analysis of the motion sensitivity of the various axes of the machine tools, the cutting parameters of the cutting tools and the axis of the machine tools are obtained by optimizing the minimum error of the tooth surface. The results show that: (1) the high precision machining of the topologically modified tooth surface can be achieved according to the back calculation of the tooth profile of the tooth profile modification tooth surface, and the CNC five axis joint forming grinding can be carried out. (2) when the plane grinding wheel is grinding the teeth, the direction pressure angle, the spiral angle and the spreading angle can be carried out to a certain diagonal modification, and the machine tool increases the tooth direction. Movement, can reduce the radius of the plane grinding wheel, used for grinding large spiral angle, large tooth width diagonal helical gear; (3) when the hob has teeth to repair the shape, and then increase the reasonable tangential movement, making the rolling process, the continuous change of the tooth shape along the direction of the tooth, make up the tooth distortion produced by the traditional machining, shape the shape of the hob and increase the tangent movement. A certain topology modification tooth surface machining can be realized; (4) when the cone grinding wheel moves along the axial stroke, the radial position of each stroke and the total stroke number of the grinding wheel are determined by the same roughness grinding method. Compared with the common uniform speed expansion and the radial average speed spreading gear grinding method, the theoretical roughness can be reduced significantly. This method can be more complex in grinding. When grinding wheel along the tooth to grinding the diagonal gear, the direction of the grinding wheel is consistent with the direction of the contact line, and the additional motion of the workpiece is solved according to the principle of development. The numerical control programming is simple. The key technology is the accurate tool of the meshing point. The correctness of the method is verified by the diagonal modification and grinding test. (5) in order to further reduce the wheel A high order transmission error tooth surface design method considering the tooth spreading is proposed. By optimizing the minimum error amplitude of the bearing transmission, the curve and the processing parameters are determined. The bearing transmission error of the 2 order, 4 order and high order transmission error tooth surface of the helical gear is compared. The amplitude of the dynamic error increases continuously; with the increase of the load, the clearance of the tooth surface decreases gradually, the reclosing degree is increasing, the amplitude of the bearing transmission error is gradually reduced. When the clearance of the tooth surface is completely eliminated, the coincidence degree is no longer changed. With the increase of the load, the amplitude of the bearing and transmission error increases gradually; for the high joint gear pair, the high order transmission error Tooth Surface It is more effective to reduce the amplitude of the bearing transmission error, because its degree of freedom is higher and is more conducive to reducing the change of the coincidence degree caused by the meshing of multi teeth. Through the curvature analysis of the modified tooth surface, it is proved that the plane grinding wheel is feasible and does not interfere with the high order transmission error tooth surface. In addition, a kind of contact mark is proposed. The inner concave high order transmission error tooth surface fully proves that it can effectively reduce the amplitude of the gear bearing transmission error, and its concave degree is affected by the load size. (6) the tooth surface vibration test shows that the modified gear has better dynamic performance, and the transmission error and vibration amplitude can be reduced by 30% or more at the design load. The objective theory method can be used in engineering practice.
【学位授予单位】：西北工业大学
【学位级别】：博士
【学位授予年份】：2015
【分类号】：TH132.41
，

本文编号：1996526