齒輪刮削與刮齒刀參數設計

Studies on the Gear Shaving and the Parameters Design of Shaving Cutter

初長軒(Chang-Hsuan Chu)

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(2008年)

摘要

刮齒刀的設計與製造由於設計理論複雜，機具開發困難，因此，到目前為止擁有刮齒刀設計與製造能力的國家並不多，國內於近幾年才建立刮齒刀的設計與製造能力，但由於未能充份掌握設計理論，故尚未能有效掌握刮齒刀的品質。就刮削同一齒輪而言，刮齒刀的設計可有許多不同選擇，何者能有較佳的刮削效果、齒形控制、壽命…等，一直為產業界與學術界共同追求的課題。
本研究將探討不同刮齒刀設計參數以加工同一齒輪時之強度，並探討被刮削齒輪之齒形。由於利用有限元素分析法模擬刮齒刀刮削齒輪時網格、節點數眾多，為求得最佳之刮齒刀設計參數，本研究首先利用田口實驗法規劃，以進行具滾製根槽之刮齒刀在不同設計參數下之刮削實驗配置，並進行有限元素分析比較，以了解不同設計參數刮齒刀之強度並減少被刮削齒輪之中凹現象。本研究，首先不考慮刮齒刀之插槽，進行其刮削模擬與被刮削齒輪齒形預測，隨後並考慮插槽參數的影響，以了解插槽齒厚對刮齒刀應力與被刮削齒輪齒形中凹的影響。後續針對鑽孔與滾製根槽對齒形的中凹進行比較，以了解根槽之外形的影響。本研究的成果可以促進業界對刮齒刀設計之了解，縮短刀具設計時間，提高刮齒刀設計、製造品質、刀具強度與使用壽命。

關鍵字

刮齒刀 ； 有限元素分析 ； 田口法 ； 插槽

並列摘要

At present, a few countries have shaving cutter design and manufacture ability due to its complex design theory and complicated machine tools. Recently, the local company has the ability of design and manufacture through a long-time development. Because the design theory is not well understood, the quality of shaving cutter cannot be well controlled until now. The shaving cutters may have different design parameters for the same shaved gear. The optimum design of shaving cutter with a long life cycle and ease of tooth profile control is highly demanded in the industry.
This thesis studies the strength of shaving cutters and the shaved gears tooth profile in the shaving process by using the finite element method. Due to the large amount of grids and nodes in this analysis, Taguchi Method is applied as the optimum tool to study the optimum design parameters of shaving cutters with novel relief portion. The phenomenon of concave tooth profile in the shaved gears is also investigated. Firstly, the shaving process between the shaving cutters without serration and the shaved gears is studied in this project. Secondly, the shaving process between the shaving cutters with serration and the shaved gears is studied. Then, the effect of the serration width can then be investigated. The concave phenomenons are studied by considering the relief portions manufactured by drilling and hobbing. In conclusion, the results of this thesis can help the local companies improving the quality of their products.

並列關鍵字

Shaving cutter ； finite element method ； Taguchi Method ； serration

參考文獻

1.Samputensili, Catalogue of SU, Bologna Italy (September 1990).

2.陳永甡，“齒輪/機械設計之研究”，機械月刊，第二十五卷，第九期，pp.278-289, 1999。

3.Litvin, F. L., Gear Geometry and Applied Theory, PTR Prentice Hall, 1994.

4.Miao, H. C. and Koga H., “Design and Analysis of Plunge Shaving for Finishing Gears with Tooth Profile Modifications,” ASME, Power Transmission and Gearing Conference, DE-Vol. 88, pp275-281, 1996.

5.Koga, H., Umezawa, K., and Miao, H. C., “Analysis of Shaving Processing for Helical Gears with Tooth Modification,” ASME, Power Transmission and Gearing Conference, DE-Vol. 88, pp265-273, 1996.