螺旋成形製程控制方法研究

A Study with Method of Controlled on Spinnig Process

張燦勳 ； 李昀浚 ； 石伊蓓 ； 蔡國棟

《鍛造》 24卷3期 (2015/10) Pp. 16-23

摘要

圓柱螺旋齒輪以擠製（Extrusion）製造為一種極具效率的量產方法，然其因受力擠出產生的內應力相當大，易造成變形而影響齒輪精度。以Deform 3D模擬擠製程序，能有效預測齒輪變形。本研究提出一個用於圓柱螺旋擠製製程的齒形誤差補償方式。Deform 3D模擬擠製製程，並以STL三角網格檔形式匯出模擬結果，我們提出一個快速STL齒面誤差分析方法，對其輸出齒面進行量測得出誤差值，並將誤差值反向疊加至模仁齒形後作為補償目標。由於擠製模具有其製造與幾何限制，我們選擇以改變齒輪參數的方式來進行補償，藉由微調端面輪廓（壓力角、轉位係數）和螺旋角來調整模具。三個參數透過最小平方法以數值方式求解，以最小化補償後模具與補償目標之間的誤差，最後透過撰寫Visual C#程式使用SolidWorks API對補償後的齒形進行齒輪自動化快速3D建模。

關鍵字

圓柱螺旋齒輪 ； 擠製 ； STL齒面誤差分析 ； 模具修正

並列摘要

Extrusion is widely viewed as a very high efficiency process for cylindrical gear manufacturing, but low precision and deformation due to internal stress are their inevitable defects. The extrusion deformation can be predicted effectively using software Deform 3D. This paper provides a method for flank topographic correction of extruded helical gear. The tooth geometry of simulating result is exported to a STL file. A STL tooth surface deviation method is proposed in this paper to evaluate errors of tooth surfaces compared with theoretical ones. The topographic deviations are superimposed to the theoretical tooth surfaces of the mold in opposite direction to obtain the modified target. The pressure angle, profile shift coefficient, and helical angle are chosen as design variables because the geometric extrusion constrains of mold. Three parameters are solved using the least squares method, so that the difference between tooth surfaces of modified mold and target can be minimized. Finally, we develop a visual C# program to automatically build 3D model of gear using SolidWorks API functions.

並列關鍵字

Helical gear ； extrusion ； STL tooth surface deviation analysis ； correction of mold