本文關(guān)鍵詞： 擺線(xiàn)齒輪 五軸高速端銑 動(dòng)態(tài)銑削力彎扭剪耦合銑削變形 軸向切深極限 顫振穩(wěn)定域 多目標(biāo)參數(shù)優(yōu)化　出處：《華僑大學(xué)》2016年博士論文　論文類(lèi)型：學(xué)位論文

【摘要】：國(guó)產(chǎn)擺線(xiàn)針輪減速器的品質(zhì)缺陷主要表現(xiàn)為傳動(dòng)精度差、運(yùn)動(dòng)不平穩(wěn),承載能力和壽命低。造成這些問(wèn)題的根本原因是擺線(xiàn)齒輪齒面的精加工技術(shù)問(wèn)題。目前國(guó)內(nèi)普遍采用磨床精加工擺線(xiàn)齒輪的齒面,由于刀具結(jié)構(gòu)等原因,加工后擺線(xiàn)齒輪的齒形精度和表面質(zhì)量都較差,致使擺線(xiàn)針輪減速器的傳動(dòng)精度、傳動(dòng)平穩(wěn)性以及減速機(jī)的壽命大為降低。這一問(wèn)題在小型擺線(xiàn)針輪減速器的制造中尤為突出。突破高檔擺線(xiàn)針輪減速器制造問(wèn)題的關(guān)鍵在于保證擺線(xiàn)齒輪齒面的精加工質(zhì)量和高效率。為此,本文以五軸高速端銑精密擺線(xiàn)齒輪為研究背景,重點(diǎn)圍繞五軸高速端銑擺線(xiàn)齒輪刀具軌跡規(guī)劃方法、擺線(xiàn)齒輪銑削力及耦合銑削變形模型構(gòu)建、擺線(xiàn)齒輪銑削顫振穩(wěn)定域分析及銑削參數(shù)優(yōu)化、擺線(xiàn)齒輪高速端銑試驗(yàn)及精度分析等關(guān)鍵技術(shù)展開(kāi)研究,主要研究?jī)?nèi)容如下:(1)提出五軸端銑擺線(xiàn)齒輪無(wú)干涉刀具軌跡規(guī)劃方法。結(jié)合刀具前傾角和側(cè)傾角,建立端銑刀有效切削橢圓數(shù)學(xué)模型,推導(dǎo)出端銑刀切削寬度近似計(jì)算公式,提出利用前傾角和側(cè)傾角分別解決端銑刀局部干涉與刀桿碰撞干涉問(wèn)題的方法。得出無(wú)干涉加工擺線(xiàn)齒輪刀軸前傾角的計(jì)算公式;獲得加工擺線(xiàn)齒輪外凸和內(nèi)凹齒廓曲面處的行距表達(dá)式。建立端銑擺線(xiàn)齒輪的幾何模型和五軸數(shù)控仿真模型,獲得其刀具軌跡。通過(guò)實(shí)例數(shù)控仿真,表明各參數(shù)設(shè)置合理,加工軌跡均勻順暢,分布合理,無(wú)加工干涉。(2)建立擺線(xiàn)齒輪動(dòng)態(tài)銑削力及耦合銑削變形模型�；谇邢髁ο禂�(shù)辨識(shí)試驗(yàn)獲得刀具-工件的切削力系數(shù),基于瞬時(shí)剛性銑削力公式建立端銑刀動(dòng)態(tài)銑削力模型,并依據(jù)該模型進(jìn)行端銑擺線(xiàn)齒輪銑削力仿真�；趶椥粤W(xué)理論建立擺線(xiàn)齒輪在銑削過(guò)程中彎扭剪耦合銑削變形模型。利用ANSYS對(duì)擺線(xiàn)齒輪的銑削變形進(jìn)行有限元分析,得到在銑削過(guò)程中沿?cái)[線(xiàn)齒輪圓周方向的銑削變形規(guī)律及不同銑削參數(shù)對(duì)擺線(xiàn)齒輪應(yīng)力應(yīng)變的影響。(3)建立刀具-工件的動(dòng)力學(xué)數(shù)學(xué)模型,提出預(yù)測(cè)銑削穩(wěn)定性軸向切深極限的計(jì)算方法。將整個(gè)加工系統(tǒng)分為“刀具-主軸”和“工件-夾具”兩個(gè)子系統(tǒng),分別進(jìn)行實(shí)驗(yàn)?zāi)B(tài)分析,獲得系統(tǒng)在不同條件下的相應(yīng)的頻率響應(yīng)函數(shù)和模態(tài)參數(shù)。繪制得到表征主軸轉(zhuǎn)速和軸向切深對(duì)應(yīng)關(guān)系的顫振穩(wěn)定域葉瓣圖;最后通過(guò)對(duì)擺線(xiàn)齒輪端銑加工實(shí)驗(yàn)驗(yàn)證該顫振穩(wěn)定域解析算法的準(zhǔn)確性。(4)以擺線(xiàn)齒輪的精加工工藝為研究對(duì)象,提出基于加工系統(tǒng)動(dòng)力學(xué)特性的銑削參數(shù)多目標(biāo)優(yōu)化方案。以主軸轉(zhuǎn)速、每齒進(jìn)給量、軸向切深和徑向切深為設(shè)計(jì)變量,以最大生產(chǎn)率、最低加工成本為綜合優(yōu)化目標(biāo)函數(shù),從機(jī)床性能、刀具性能以及加工質(zhì)量等三方面進(jìn)行約束條件界定,構(gòu)建銑削參數(shù)多目標(biāo)優(yōu)化模型。將加工系統(tǒng)的穩(wěn)定性作為關(guān)鍵的約束條件來(lái)進(jìn)行銑削參數(shù)優(yōu)化,成功地實(shí)現(xiàn)擺線(xiàn)齒輪加工的銑削參數(shù)優(yōu)化。仿真和試驗(yàn)結(jié)果表明:采用優(yōu)化后的銑削參數(shù)進(jìn)行擺線(xiàn)齒輪加工,能提高加工表面質(zhì)量,并一定程度減少刀具變形,降低了加工成本。(5)設(shè)計(jì)擺線(xiàn)齒輪數(shù)控加工工藝路線(xiàn),利用五軸聯(lián)動(dòng)立式加工中心實(shí)現(xiàn)擺線(xiàn)齒輪的高速端銑加工,得到精加工的擺線(xiàn)齒輪樣件。提出擺線(xiàn)齒輪齒廓曲面的三坐標(biāo)測(cè)量和誤差評(píng)定方法。利用接觸式輪廓儀對(duì)擺線(xiàn)齒輪齒廓曲面的粗糙度進(jìn)行測(cè)量。該試驗(yàn)驗(yàn)證高速端銑擺線(xiàn)齒輪的加工方法可以達(dá)到磨削擺線(xiàn)齒輪的加工精度,從而實(shí)現(xiàn)擺線(xiàn)齒輪加工的“以銑代磨”,提高加工效率。
[Abstract]:Domestic cycloid reducer quality defects mainly for transmission precision, unstable movement, bearing capacity and low life. The root causes of these problems is the problem of the cycloid gear tooth surface finishing technology. Currently widely used grinding machining cycloid gear tooth surface, the tool structure and other reasons, after processing the cycloid the gear tooth shape precision and surface quality are poor, resulting in the transmission precision reducer cycloid reducer, transmission stability and the service life is greatly reduced. The problem of reducer manufacturing especially in small cycloid. Breakthrough high-end cycloid reducer manufacturing problems is the key to ensure the cycloid gear the tooth surface machining quality and efficiency. Therefore, this paper takes five axis high speed end milling precision cycloidal gear as the research background, focus on five axis high speed milling tool path planning of cycloidal gear The construction method, deformation model of cycloid gear milling force and milling chatter stability coupling, cycloid gear milling analysis and optimization of cutting parameters, carried out research on the key technology of cycloid gear high speed end milling experiment and accuracy analysis, the main research contents are as follows: (1) proposed five axis end milling cycloidal gear interference free tool path planning method. Combined with the tool inclination and tilt angles, establish effective mathematical model of end milling cutting ellipse, end milling cutter width approximate calculation formula is derived. The proposed interference problem method using inclination and tilt angles respectively solve the end milling cutter bar and local interference collision is obtained. The computation formula of interference processing cycloidal gear cutter shaft anteversion; space expression processing cycloidal gear and convex concave tooth profile surface is obtained. A geometric model of end milling cycloidal gear and five axis NC simulation model, the tool path. The example shows that the numerical simulation, the reasonable parameters, processing path is uniform and smooth, reasonable distribution, without processing the interference. (2) establish the cycloid gear dynamic milling force and milling deformation coupling model. The cutting force coefficient of cutting force coefficients identification test tool workpiece based on instantaneous rigid milling force formula of end milling dynamic milling force based on the model, and on the basis of the model for end milling of cycloid gear milling force simulation. Elastic mechanics theory to establish the cycloid gear in the milling process coupled flexural torsional shearing milling deformation. Using ANSYS model based on milling of cycloidal gear deformation finite element analysis during milling milling along the circumferential direction of the cycloid gear deformation and different milling parameters the influence of stress and strain of cycloid gear. (3) the establishment of dynamic mathematical model of the tool workpiece, the milling stability is proposed to predict the axial cutting depth limit 璁＄畻鏂規(guī)硶.灝嗘暣涓姞宸ョ郴緇熷垎涓衡，

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