利用SolidWorks API進行戟齒輪加工機切削模擬方法研究

郭哲甫(ZHE-FU GUO)

指導教授 ： 馮展華

國立中正大學/工學院/機械工程學系/碩士(2013年)

摘要

本研究建立泛用座標之間的轉換式，利用Visual Basic程式語言搭配SolidWorks API函式庫，開發戟齒輪加工機切削模擬系統。該模擬系統與德國Klingelnberg公司所提出之泛用型數學模式相容，能夠模擬目前面銑式(Face Milling Method)所有切削加工方法，包含成形法(Formate Mathod)、雙齒腹切削法(Duplex Cutting)及單齒切削法(Fixed Setting)，透過空間中刀具及工件之機械設定關係以及利用SolidWorks之內建體積干涉功能將刀具及工件之體積重疊部分移除，而切削模擬後可得3D模型，並同時計算體積移除曲線。透過模擬後之3D模型與理論齒形作法向拓樸誤差分析，驗證機械設定參數之正確性，並且可解決理論解高次非線性之數值發散的情形，以提供更精準之加工設定參數及縮短產品開發製造週期。

關鍵字

轉換 ； SolidWorks API ； 泛用座標 ； 切削模擬

並列摘要

The goal of this thesis is to develop a cutting simulation software for the hypoid gear generator using Visual Basic and SolidWorks API. The basic mathematical model of proposed simulation software is compatible with the universal hypoid generator model developed by the Klingelnberg GmBH. The proposed simulation software is able to simulate the hypoid gear cutting by the face milling method, including the plunge cutting (Formate method), duplex generating cutting (Helical Duplex method), and single-side generating cutting (Fixed Setting method). The spatial relationship between head cutter and the workpiece is determined by the machine settings of the universal hypoid generator. The intersecting volume between head cutter and workpiece is subtract from workpiece by SolidWorks Boolean subtract function according to the cutting program. The volume removal rate on the workpiece is recorded as a function of cutting time which can be used to analyze the cutting force history during cutting. After cutting simulation is completed, the remaining volume of workpiece is the 3D model of the generated hypoid gear. The proposed cutting simulation software is verified by comparing the 3D model generated by the proposed simulation software with the theoretical tooth surface data provided by the KIMoS software of Klingelnberg. Since the tooth cutting simulation is done by the volumetric Boolean subtract, the proposed simulation methodology is more numerically stable than calculating the tooth surface coordinate by solving highly nonlinear simultaneous system equations. The proposed hypoid cutting simulation software can be used to verify the machine settings for hypoid gear cutting before real manufacturing is taking place.

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