【摘要】：制造業(yè)的快速發(fā)展使人們的生活水平不斷提高,而人們對產(chǎn)品的多樣性、個(gè)性化需求又刺激制造業(yè)不斷革新技術(shù),創(chuàng)造新產(chǎn)品。齒輪作為制造業(yè)中基礎(chǔ)的傳動(dòng)零件之一,需求量日益增大,精度及性能要求也不斷提高。滾齒切削是齒輪加工的主要方式之一,在滿足產(chǎn)品需求的基礎(chǔ)上生產(chǎn)效率更高。由于滾齒過程為復(fù)雜的多刃斷續(xù)切削過程,過程復(fù)雜性決定了需要尋求更加有效的方法對其切削加工機(jī)理進(jìn)行分析,以了解滾齒切削參數(shù)對切削力、切削溫度以及刀具磨損的影響規(guī)律,進(jìn)而為滾齒技術(shù)的發(fā)展奠定基礎(chǔ),使傳統(tǒng)的滾齒切削方式向著更為節(jié)能、高效的方向發(fā)展。本文基于滾齒過程中滾刀和工件的幾何運(yùn)動(dòng)關(guān)系,以SolidWorks軟件為平臺,構(gòu)建滾齒加工幾何仿真模型,模擬滾齒切削過程,從而為建立有限元仿真的三維模型、計(jì)算分析滾齒過程中的切削力奠定基礎(chǔ)。利用遺傳算法對滾齒切削參數(shù)進(jìn)行優(yōu)化,降低生產(chǎn)成本,提高加工效率,減少由于試切造成的資源浪費(fèi),將企業(yè)效益最大化。本文的主要研究工作如下:首先,運(yùn)用滾齒運(yùn)動(dòng)關(guān)系數(shù)學(xué)模型,分析滾刀刀齒獲得的切屑的形狀和大小。利用加工過程中滾刀和工件的運(yùn)動(dòng)關(guān)系,分別建立二維滾齒狀態(tài)和三維滾齒狀態(tài)下的數(shù)學(xué)模型,使用MATLAB求解滾刀刀齒在二維和三維狀態(tài)下運(yùn)動(dòng)軌跡上的坐標(biāo)點(diǎn),分析滾刀刀齒每齒切削面積;把KYTool作為SolidWorks插件,使用C+語言對SolidWorks進(jìn)行二次開發(fā),使其可以按照指令利用刀齒空間坐標(biāo)點(diǎn)進(jìn)行幾何過程仿真,研究滾刀刀齒的每齒切削體積,分析刀齒切削刃的切削狀態(tài);同時(shí)利用SolidWorks二次開發(fā)法提取三維切屑模型表面上點(diǎn)的坐標(biāo),并驗(yàn)證提取結(jié)果的有效性。其次,利用SolidWorks幾何仿真得到的工件模型和切屑模型,分別運(yùn)用解析法和有限元法計(jì)算滾齒切削力。前者通過提取切屑三維模型表面上點(diǎn)的空間坐標(biāo),利用切屑形狀,以微元法計(jì)算切削力;后者將工件三維模型導(dǎo)入ABAQUS中進(jìn)行滾齒仿真,計(jì)算滾齒切削力,并將二者的結(jié)果進(jìn)行對比分析,驗(yàn)證計(jì)算結(jié)果的正確性。采用有限元仿真分析了滾齒過程中滾齒切削參數(shù)對切削力的影響,為切削參數(shù)的選取提供理論依據(jù)。最后,對滾齒過程中的切削參數(shù)和切削功率進(jìn)行研究。設(shè)計(jì)了滾齒切削實(shí)驗(yàn)測量滾齒切削功率,將實(shí)驗(yàn)得到的平均切削功率與解析計(jì)算得到的平均切削功率進(jìn)行對比,驗(yàn)證計(jì)算結(jié)果的正確性;利用遺傳算法對滾齒切削參數(shù)進(jìn)行多目標(biāo)優(yōu)化,使?jié)L齒達(dá)到單件加工成本最低,加工時(shí)間最短的目的。本研究為進(jìn)一步掌握滾齒切削機(jī)理提供技術(shù)支持,為新的滾齒加工方式—高速干式滾齒指出了新的研究方法,可以方便、快捷的為滾齒有限元仿真提供精確的三維模型,從而實(shí)現(xiàn)"以滾代磨"。
[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."
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG612

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