小模数弧齿锥齿轮五轴数控加工变形分析与控制

发布时间：2018-05-30 14:19

本文选题：小模数弧齿锥齿轮 + 五轴数控加工　；参考：《湘潭大学》2017年硕士论文

【摘要】：弧齿锥齿轮具有承载能力强、重叠系数高以及传动平稳等优点,在精密仪器、钻探设备、重载汽车、远洋船舶等领域具有广泛的应用。目前,小模数弧齿锥齿轮传动中一般都采用修正摆线齿形,而加工方式的不同直接影响到齿形精度。由于尺寸小,存在刀具和工件的变形。因此如何建立合理的刀轨优化算法,减小加工变形是实现弧齿锥齿轮齿廓面数控高效高精加工的关键。为此,本文以小模数弧齿锥齿轮五轴数控加工为研究对象,综合运用五轴数控加工理论、刀具包络面理论、两点偏置法、有限元数值模拟技术等理论和手段,探索弧齿锥齿轮齿廓面加工变形,并对其实现有效控制,具体研究工作如下:(1)小模数弧齿锥齿轮的实体模型的建立和五轴数控加工刀轨的规划。利用UG建模弧齿锥齿轮的空间实体,通过分析弧齿锥齿轮的几何特征与结构特点,确定加工的参数,建立了基于模型特征的五轴数控加工刀轨规划方案,依托UG软件CAM模块对加工刀轨方案进行了分析。(2)齿廓精铣加工刀轨优化及误差分析。通过(1)建立的刀轨规划,基于单参数球族包络理论,运用MATLAB建立了齿廓面侧铣过程中的刀具包络面,对弧齿锥齿轮侧铣加工的齿廓面离散化,通过分析理论齿廓面与刀具包络面之间的法向误差,采用两点偏置法优化刀轴减少误差,重新建立了侧铣加工过程中精加工刀轨,减小侧铣过程中的误差量。(3)弧齿锥齿轮齿廓面加工变形分析。建立了小模数弧齿锥齿轮侧铣加工齿廓面变形与刀具变形的理论预测模型,结合铣削力模型及AdvantEdge PM模拟仿真,计算出理论变形量;运用ANSYS平台将实时铣削力导入,建立侧铣加工的有限元模型,分析侧铣加工中的齿廓变形以及刀具变形值,通过与理论预测模型的对比,探究侧铣时齿面与刀具变形分布规律;通过运用AdvantEdge PM模块优化侧铣过程中的切削参数,来优化铣削力,最终减小侧铣过程中出现的齿面和刀具的变形误差。(4)弧齿锥齿轮加工仿真与试验验证。基于Vericut7.3对弧齿锥齿轮进行加工仿真,然后通过加工试验及三坐标测量仪测量,对实际加工齿廓面与理论齿廓面的误差分析,验证了刀轨优化与控制加工变形的有效性。综上,本文的研究为小模数弧齿锥齿轮高精加工提供了参考依据,为提升我国小模数弧齿锥齿轮数控加工工艺水平奠定了理论基础。
[Abstract]:The spiral bevel gear has the advantages of strong bearing capacity, high overlap coefficient and smooth transmission. It has extensive application in the fields of precision instrument, drilling equipment, heavy vehicle, ocean ship and so on. At present, the modified cycloid gear is usually used in the small modulus spiral bevel gear transmission, and the difference of processing mode directly affects the tooth shape precision. It is small in size and has the deformation of tool and workpiece. Therefore, how to establish a reasonable algorithm of tool rail optimization and reduce the processing deformation is the key to realize the high efficiency and high precision machining of the tooth profile surface of the spiral bevel gear. In this paper, the five axis NC machining of the small modulus spiral bevel gear is used as the research object, and the five axis NC machining theory and the tool envelope surface are used in this paper. The theory, the two point bias method, the finite element numerical simulation technology and other theories and means to explore the machining deformation of the tooth profile of the spiral bevel gear, and to control it effectively. The specific research work is as follows: (1) the establishment of the solid model of the small modulus spiral bevel gear and the planning of the five axis NC machining tool rails. The space entity of the spiral bevel gear is modeled by UG. By analyzing the geometric features and structural features of the spiral bevel gear and determining the parameters of the machining, the five axis NC machining tool rail planning scheme based on the model features is established. The tool rail scheme is analyzed based on the UG software CAM module. (2) the tool rail optimization and error analysis of the tooth profile finishing. The tool rail planning based on (1) is based on single parameter. The envelope theory of the number ball family is used to establish the tool envelope surface in the tooth profile side milling process, and the tooth profile surface of the spiral bevel gear side milling is discretized. By analyzing the normal error between the theoretical tooth profile and the tool envelope surface, the two point bias method is used to optimize the cutter shaft to reduce the error, and the finishing tool in the side milling process is reestablished. The error quantity in the side milling process is reduced. (3) the analysis of the machining deformation of the tooth profile surface of the spiral bevel gear. The theoretical prediction model of the tooth profile surface deformation and the tool deformation of the small modulus spiral bevel gear milling is established, and the theoretical deformation amount is calculated by the milling force model and the simulation simulation of AdvantEdge PM, and the real-time milling force is introduced by the ANSYS platform, The finite element model of side milling is established, and the tooth profile deformation and tool deformation value in side milling are analyzed. By comparing with the theoretical prediction model, the distribution law of tooth surface and tool deformation in side milling is explored. By using the AdvantEdge PM module to optimize the cutting parameters in the side milling process, the milling force is optimized and the end milling process is finally reduced. The deformation error of the present tooth surface and the cutting tool. (4) the machining simulation and test verification of the spiral bevel gear. Based on the machining simulation of the spiral bevel gear, the error analysis of the actual tooth profile surface and the theoretical tooth profile is analyzed by the processing test and the three coordinate measuring instrument, and the effectiveness of the tool track optimization and the control machining deformation is verified. In summary, the research of this paper provides a reference for the high precision machining of small modulus spiral bevel gear. It lays a theoretical foundation for improving the NC machining technology level of small modulus spiral bevel gear in China.
【学位授予单位】：湘潭大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG659;TG61

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