滚齿加工切削力分析及切削参数优化

发布时间：2019-01-13 08:43

【摘要】：制造业的快速发展使人们的生活水平不断提高,而人们对产品的多样性、个性化需求又刺激制造业不断革新技术,创造新产品。齿轮作为制造业中基础的传动零件之一,需求量日益增大,精度及性能要求也不断提高。滚齿切削是齿轮加工的主要方式之一,在满足产品需求的基础上生产效率更高。由于滚齿过程为复杂的多刃断续切削过程,过程复杂性决定了需要寻求更加有效的方法对其切削加工机理进行分析,以了解滚齿切削参数对切削力、切削温度以及刀具磨损的影响规律,进而为滚齿技术的发展奠定基础,使传统的滚齿切削方式向着更为节能、高效的方向发展。本文基于滚齿过程中滚刀和工件的几何运动关系,以SolidWorks软件为平台,构建滚齿加工几何仿真模型,模拟滚齿切削过程,从而为建立有限元仿真的三维模型、计算分析滚齿过程中的切削力奠定基础。利用遗传算法对滚齿切削参数进行优化,降低生产成本,提高加工效率,减少由于试切造成的资源浪费,将企业效益最大化。本文的主要研究工作如下:首先,运用滚齿运动关系数学模型,分析滚刀刀齿获得的切屑的形状和大小。利用加工过程中滚刀和工件的运动关系,分别建立二维滚齿状态和三维滚齿状态下的数学模型,使用MATLAB求解滚刀刀齿在二维和三维状态下运动轨迹上的坐标点,分析滚刀刀齿每齿切削面积;把KYTool作为SolidWorks插件,使用C+语言对SolidWorks进行二次开发,使其可以按照指令利用刀齿空间坐标点进行几何过程仿真,研究滚刀刀齿的每齿切削体积,分析刀齿切削刃的切削状态;同时利用SolidWorks二次开发法提取三维切屑模型表面上点的坐标,并验证提取结果的有效性。其次,利用SolidWorks几何仿真得到的工件模型和切屑模型,分别运用解析法和有限元法计算滚齿切削力。前者通过提取切屑三维模型表面上点的空间坐标,利用切屑形状,以微元法计算切削力;后者将工件三维模型导入ABAQUS中进行滚齿仿真,计算滚齿切削力,并将二者的结果进行对比分析,验证计算结果的正确性。采用有限元仿真分析了滚齿过程中滚齿切削参数对切削力的影响,为切削参数的选取提供理论依据。最后,对滚齿过程中的切削参数和切削功率进行研究。设计了滚齿切削实验测量滚齿切削功率,将实验得到的平均切削功率与解析计算得到的平均切削功率进行对比,验证计算结果的正确性;利用遗传算法对滚齿切削参数进行多目标优化,使滚齿达到单件加工成本最低,加工时间最短的目的。本研究为进一步掌握滚齿切削机理提供技术支持,为新的滚齿加工方式—高速干式滚齿指出了新的研究方法,可以方便、快捷的为滚齿有限元仿真提供精确的三维模型,从而实现"以滚代磨"。
[Abstract]:With the rapid development of manufacturing industry, people's living standard is improving constantly, and people's diversity of products and individualized demand stimulate manufacturing industry to innovate technology and create new products. As one of the basic transmission parts in the manufacturing industry, the demand for gear is increasing day by day, and the precision and performance requirements are also improved. Gear hobbing cutting is one of the main ways of gear machining, and the production efficiency is higher on the basis of satisfying the demand of products. Because the hobbing process is a complex multi-blade intermittent cutting process, the complexity of the process makes it necessary to find a more effective method to analyze the cutting mechanism in order to understand the cutting force of the hobbing cutting parameters. The influence of cutting temperature and tool wear has laid a foundation for the development of hobbing technology and made the traditional hobbing cutting more energy efficient and efficient. Based on the geometric motion relation between hob and workpiece in the process of hobbing, the geometric simulation model of hobbing machining is constructed on the platform of SolidWorks software, and the process of hobbing cutting is simulated in order to establish the three-dimensional model of finite element simulation. Calculation and analysis of the cutting force in the hobbing process lay the foundation. Genetic algorithm is used to optimize the hobbing cutting parameters to reduce the production cost, improve the processing efficiency, reduce the waste of resources caused by trial cutting, and maximize the benefit of the enterprise. The main work of this paper is as follows: firstly, the shape and size of chip obtained from hob teeth are analyzed by using the mathematical model of hobbing motion relationship. Based on the kinematic relationship between hob and workpiece in machining process, the mathematical models of 2-D and 3D hobbing states are established, and the coordinate points on the motion trajectory of hob teeth in 2D and 3D states are solved by using MATLAB. The cutting area of each tooth of hob teeth is analyzed. Taking KYTool as the SolidWorks plug-in, the SolidWorks is redeveloped with C language, which can be used to simulate the geometric process by using the spatial coordinate points of the cutter teeth according to the instruction, to study the cutting volume of each tooth of the hob teeth, and to analyze the cutting state of the cutting edge of the cutter teeth. At the same time, the coordinates of the points on the surface of the 3D chip model are extracted by using the SolidWorks secondary development method, and the validity of the extracted results is verified. Secondly, the workpiece model and chip model obtained by SolidWorks geometric simulation are used to calculate the cutting force of hobbing gear by analytic method and finite element method, respectively. In the former, the spatial coordinates of the points on the surface of the chip 3D model are extracted, and the cutting force is calculated by the micro-element method using the chip shape. The latter introduces the 3D model of workpiece into ABAQUS for hobbing simulation, calculates the cutting force of hobbing, and compares the results of the two to verify the correctness of the calculation. The influence of hobbing parameters on cutting force is analyzed by finite element simulation, which provides a theoretical basis for the selection of cutting parameters. Finally, the cutting parameters and cutting power in the hobbing process are studied. The experiment of hobbing cutting is designed to measure the cutting power of the hobbing teeth. The experimental average cutting power is compared with the analytical average cutting power to verify the correctness of the calculation results. The multi-objective optimization of hobbing parameters is carried out by genetic algorithm (GA), which makes the hobbing achieve the goal of minimum cost and shortest processing time. This study provides technical support for further mastering the mechanism of hobbing, and points out a new research method for the new hobbing machine-high-speed dry hobbing, which can provide accurate 3D model for the finite element simulation of hobbing. In order to achieve "rolling instead of grinding."
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG612

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