鉋齒刀之切削模擬與剛性分析

Cutting Simulation and Stiffness Analysis of Shaper Cutter

洪新堡(Xin-Bao Hong)

指導教授 ： 張信良

國立虎尾科技大學/工程學院/機械與機電工程研究所/碩士(2011年)

摘要

鉋齒刀鉋製齒輪時，所受的切削力與鉋齒切削過程中每一次切削所切除的切削量有關，因此本研究利用Visual Basic程式語言搭配SolidWorks API函式庫，撰寫鉋齒機虛擬實驗平臺系統，此界面可以連接SolidWorks，控制內部功能並繪製鉋齒刀與齒胚，決定好相對位置與相對運動關係後，經過輸入加工參數，就可進行伸長除料的指令動作，並將每一次切除的切削量計算並輸出，經過數次模擬衝程後，即可得到切削過程中，切削量的變化、最大、最小切削量及所切製的齒輪模型，以作為後續研究之用。
而鉋齒刀的本體設計各國大多訂有參考規範，依此設計之刀具剛性在使用上較無問題，但若需依使用條件或機台限制而調整參數時，則無法預測鉋齒刀之變形是否仍能符合需求，進而造成齒形S型誤差問題。因此本研究以JIS規格為例，利用SolidWorks繪出鉋齒刀，再藉由SolidWorks Simulation 進行鉋齒刀受力虛擬實驗，並搭配參數變化與迴歸分析法，建立迴歸方程式，以做為客戶變更鉋齒刀參數後的刀具剛性指標，成果並可應用至其他各國規範。

關鍵字

鉋齒刀 ； Visual Basic ； SolidWorks API ； 迴歸分析法 ； 剛性指標

並列摘要

In the process of gear shaping, the cutting force is related to the stock removal in each cutting. In this study, a simulation system of the shaping machine is developed by “Visual Basic” and “SoildWorks API”. The simulation system can be connected to SolidWorks, and uses the function of SolidWorks and then build 3-D model of shaper cutter and gears. After the set up of cutter’s position and the relationship between shaper cutter and the workpiece, we can input the required working parameters. The “Extrude cut” function of SolisWorks is executed to get all the maximum and minimum stock removals in the shaping processes. The results can be applied in the further research.
Gear shaper cutters have been widely adopted for special gear tooth roughing, and in some applications the cutter body stiffness is found significant to shaped gears. There exist national standards, i.e. DIN and JIS, for shaper cutter design. Following these standards, the cutters will have better reliability, and so are the shaped gears. However in some applications with more constraints including machine stroke, clamping tool and other cutter size related issues, the shaper cutter designer needs to modify those instructions from standards without a systematic way to evaluate the cutter stiffness. Therefore in this study, taking JIS standards as an example, a parametric CAE model for shaper cutter stiffness evaluation is constructed by using SolidWorks and Simulation. The CAE model is then used in a well-planned virtual experiment for the following regression analysis. Equations for evaluating cutter stiffness are obtained after the regression analysis so that stiffness can be evaluated more easily and efficiently in the future with predefined stiffness index.

並列關鍵字

Shaper Cutters ； Visual Basic ； SolidWorks API ； Regression Analysis ； Stiffness Index

參考文獻

2.Green, R. N. and Mabie, H. H., “Determination of Static Tooth Stress in Nonstandard Spur Gears Cut by Pinion Cutter”, Mech. Mach. Theory, Vol. 15, pp. 507-514, 1980.

3.Green, R. N. and Mabie, H. H., “Determination of Pinion Cutter Offsets Required to Produce Nonstandard Spur Gears with Teeth of Equal Strength”, Mech. Mach. Theory, Vol. 15, pp. 507-514, 1980.

5.Rogers, C. A., Mabie, H. H., and Reinholtz, C. F., “Design of Spur Gears Generated with Pinion Cutters”, Mech. Mach. Theory, Vol. 25, No. 6, pp. 623-634, 1990.

10.Tsay, C. B., Liu, W. Y., and Chen, Y. C., “Spur Gear Generation by Shaper Cutters”, Journal of Materials Processing Technology, Vol. 104, pp. 271-279, 2000.

11.Wilcox, L. and Coleman, W., “Application of Finite to the Analysis of Gear Tooth Stress,” Trans. ASME, Journal of Engineering for Industry, Vol. 95, No. 4, pp. 1139-1149, 1973.