特种传动曲面五轴铣削工艺方法及工艺参数优化研究

发布时间：2017-12-28 17:38

本文关键词：特种传动曲面五轴铣削工艺方法及工艺参数优化研究　出处：《大连理工大学》2015年硕士论文　论文类型：学位论文

【摘要】：节能化、精密化高端装备的发展对传动系统的传动精度提出了更高要求。球渐开线弧齿锥齿轮是高端装备内部传动系统必不可少的关键部件,基于格里森制切齿方法的固有缺陷制约了其传动精度及加工精度的提高。为突破现有弧齿锥齿轮加工机制,以提高弧齿锥齿轮加工精度,进而以提高传动精度为目标,研究球渐开线齿形曲面的通用五轴数控加工技术。然而复杂曲面各点几何特征的非一致性导致五轴铣削过程刀具切削面积具有时变性,从而引起铣削力的剧烈波动,影响加工质量、刀具寿命,甚至导致机床振动,如何在提高球面渐开线弧齿锥齿轮制造效率情况下减小铣削力波动以提高该类零件的加工质量是该领域一项亟需解决的问题。本文突破传统专用机床加工方法实现特种传动曲面五轴数控机床切齿方法,并建立一种基于主轴转速及刀具切削面积的新型五轴加工铣削力预测模型以完成特种传动曲面加工主轴转速优选,进而在表面粗糙度的影响规律研究的基础上的工艺参数优化,具体研究内容如下：首先,根据球渐开数学方程及弧齿锥齿轮成形原理准确完成特种传动曲面参数化建模,建模时依次导入球渐开线数学模型、添加齿轮尺寸参数、扫掠齿廓并旋转变换、阵列,其中扫掠齿廓并旋转变换为建模难点；依照特种传动曲面的几何特征,在UG的加工模块环境下,设计以侧刃驱动体方式走刀的加工轨迹,并且根据模型大小对齿形面和齿根采用不同大小的刀具；初选五轴数控机床加工工艺参数主轴转速且切深和进给量采取经验参数值以完成特种传动曲面的五轴铣削加工。其次,分析球头铣刀的切触状态,经过对切削刃曲线方程的研究完成实际加工中切削过程的MATLAB仿真,分析并计算每时刻切触区域的范围,根据切深、进给量、曲面几何特征、切削刃曲线计算切削厚度,经过切削厚度对切削高度的积分计算,建立刀具切削面积的数学模型；设计并加工了具有特种传动曲面特征的实验载体,测得不同主轴转速下铣削力变化的数据,经过滤波处理后,最后以主轴转速和刀具切削面积为变量完整地得出新型铣削力预测模型的显式关系式。最后,在主轴转速优选情况下,检测不同工艺参数下加工的表面粗糙度,进而得出最佳的工艺参数；利用该参数进行全齿切削实验对优化后工艺参数进行验证,并检测该五轴数控加工技术下加工零件的齿轮精度及表面粗糙度,加工结果表现良好。
[Abstract]:The development of high - end equipment for energy saving and precision puts forward higher requirements for transmission precision of transmission system. Ball involute spiral bevel gear is an essential part of the internal drive system of high-end equipment. The inherent defects of Gleason based cutting method restrict its transmission accuracy and machining accuracy. In order to break through the existing spiral bevel gear processing mechanism and improve the machining accuracy of spiral bevel gear, and further improve the transmission accuracy, the universal five axis NC machining technology of spherical involute tooth profile is studied. However, the non consistency of complex surface geometric characteristics of each point lead to five axis milling cutter cutting area with time-varying volatility, thereby causing the milling force, affects the machining quality and tool life, and even lead to the vibration of the machine tool, how to reduce the fluctuation of milling force in improving the spherical involute spiral bevel gear manufacturing conditions to improve the processing efficiency the quality of this kind of parts in this field is an urgent problem. This paper breaks through the traditional processing method of special machine tool special drive surface of five axis NC machine tool cutting method, and to establish a predictive model to complete the special transmission surface machining spindle speed optimization based on model of five axis machining milling spindle speed and cutting area, and the surface roughness parameters of influence based on the study of optimization rules and the specific contents are as follows: firstly, according to the mathematical equation of ball involute and spiral bevel gear transmission principle of special surface parametric modeling of accurate modeling of involute ball turn into mathematical model, add gear parameters and sweep tooth profile and rotation, which swept array, tooth profile and rotation transformation for modeling according to the characteristics of special transmission difficulties; geometric surface, in the environment of UG processing module, trajectory design of feed to the side edge of the driving body, and According to the size of the model, different sizes of cutting tools are adopted for the tooth surface and root. The five axis NC machine tool is selected to process the technological parameters and spindle speed, and the depth and feed are taken as empirical parameters to complete the five axis milling of the special transmission surface. Secondly, contact state analysis of ball end milling, after the study on the cutting edge curve equation MATLAB to complete the simulation of cutting process in actual processing, analysis and calculation of each time range contact area, according to the depth of cut, feed rate, cutting edge geometry, surface curve of cutting thickness, cutting through the thickness of the integral the cutting height calculation, establish the mathematical model of cutting area; design and experimental carrier has a special transmission characteristics of surface processing, the measured variation of milling force under different spindle speed data, after filtering processing, and finally to the spindle speed and cutting area as variables obtained new explicit relation model of milling force prediction the type. Finally, in the case of spindle speed optimization, surface detection under different process parameters and processing roughness, and the optimum parameters; full tooth cutting experiment to verify the optimum parameters using this parameter, and detecting the gear precision and surface processing of parts of the five axis NC machining of the roughness, processing results good performance.
【学位授予单位】：大连理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG54

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