数字化齿面展成加工及误差补偿研究
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摘要
基于动态力学描述的数字化齿面不同于基于理想刚体描述的解析齿面。它们能够精确地反映机械运行过程中热、力引起的弹塑性变形,提高齿轮传动的准确性、工作的平稳性、载荷分布的均匀性,满足现实对设备高速,重载、高效、低噪的要求。有关数字化齿面的研究已成为现代机械设计及制造的一个重要发展方向。传统的基于几何解析的加工理论,无法对数字化齿面进行精确加工。为实现数字化齿面及类似曲面的高效、高精、高柔度加工,本学位论文对数字化齿面展成加工及误差补偿的理论与方法进行了广泛而深入的研究。
(1)数字化齿面展成加工的理论与方法研究。将共轭曲面理论与具体的数字化齿轮齿面加工工艺相结合,应用到数字化齿面展成加工中,建立了数字化齿面磨削展成加工和插削展成加工模型,为数字化齿面展成加工的实际应用提供了理论和方法指导。
(2)数字化齿面展成加工的仿真研究。以虚拟数字化齿面磨削展成加工为例,开展了数字化齿面展成加工的仿真研究。开发了一个数字化齿面加工仿真系统,对磨削模型和求解方法的正确性进行了检查; 对齿面加工连续性、加工精度和加工干涉现象等进行了校验; 为实际加工实验做好了准备。
(3)数字化齿面展成加工齿廓误差综合性分析。研究通过实际齿面测量进行数字化齿面加工齿廓误差分析的方法,建立了齿面加工齿廓误差综合模型,对整个加工齿面的齿廓误差分布形态进行了分析和评定; 并提出了相应的误差值计算算法。研制了数字化齿面加工齿廓误差综合分析软件。
(4)数字化齿面展成加工中的齿廓误差补偿研究。提出了数字化齿面加工齿廓误差预补偿策略,并依据齿面加工齿廓误差分析情况进行误差预测,重构了待加工的虚拟数字化齿面,为后续数字化齿面补偿加工提供了数值依据; 在此基础上,研制了数字化齿面齿廓误差补偿加工软件。
(5)数字化齿面展成加工实验研究。以数字化齿面插削展成加工为例,开展了数字化齿面展成加工实验研究。解决了实际数字化齿面展成加工中的多齿连续啮合
The Digital Gear Tooth Surfaces depicted with dynamics feature differ from the surfaces described on the basis of ideal rigid body in that the former can accurately reflect the elastic and plastic deformation induced by stress and heat in machine operations, thus improve the performance of the gear drive to meet the real requirements of high speed, heavy load, high efficiency and low noise. The research about digital gear tooth surfaces is becoming an important developing aspect for contemporary design & manufacture. It is difficult to generate digital gear tooth surfaces accurately by traditional manufacturing technology. In order to machining digital gear tooth surfaces with high efficiency, great accuracy and remarkable flexibility, researches on generating method and error compensation for digital gear tooth surfaces have been thoroughly carried out in this dissertation. The work covers:
(1) Research on generating method of digital tooth surfaces. Combined with the digitized theory of conjugate surface and the actual technologies for gear machining, the method to manufacture the digital tooth surface is developed. The machining models of gear grinding and shaping for digital gear tooth surfaces are established. The research offers the basic theory and means to manufacture digital gear tooth surfaces practically.
(2) Research on virtual manufacture of digital tooth surfaces with generating method. A simulation generation system like gear grinding is taken as an example to develop, which can verify the model of gear grinding and the generating method of digital tooth surfaces. At the same time, the checkout of continuity, accuracy and interference during the processing can be done. The simulation provides helps to the experiments of gear machining.
(3) Research on error analysis of machining of digital tooth surfaces. The method for extracting machining errors from the information of topography measurements on the real surfaces of physical parts is proposed. The distribution of error on the total tooth surface is analyzed and evaluated. A synthetical error model has been developed, and suitable algorithms have been presented to calculate errors. The software for error analysis is also developed.
(4) Research on error compensation of machining of digital tooth surfaces. A
‘pre-calibration error compensation’strategy is presented. The total compensation error is predicted based on this idea. A virtual digital surface is reconstructed with the prediction. This work offers the numerical value in the subsequent operations. Then, the software for error compensation is developed. (5) Research on experiments of generating machining of digital tooth surfaces. Gear shaping experiments as examples are carried out. Some factual questions such as gear continual meshing are treated with during the experiments. The gear with digitized involute tooth profile and the gear with digitized non-standard tooth profile are slotted successfully. The experiments verify the generating method of digital gear tooth surfaces proposed in this dissertation. (6) Research on slotting experiments of digital tooth surfaces based on error pre-compensation. The Gear with digitized involute tooth profile is taken as example during the experiments. The digital gear tooth surfaces are slotted successfully by the operation with error pre-compensation. The results of accuracy checking of this gear are illustrated and proved the researches mentioned above. The dissertation develops the systematic theory for generating machining of DGTS, hence breaks through the limitation of the traditional approaches based on analytic geometry. The research combining the processing techniques of gear with the technologies of digital measurement, NC machining and computer software, realized the manufacture of gear with high quality. The method presented can be directly applied in the manufacture of the digital design tooth surface and the machining of measuring reconstructed digital surface of the physical parts as well. The research provides theoretical and technical bases for the CAD/CAM technology for manufacturing of digital gear tooth surfaces.
(1)数字化齿面展成加工的理论与方法研究。将共轭曲面理论与具体的数字化齿轮齿面加工工艺相结合,应用到数字化齿面展成加工中,建立了数字化齿面磨削展成加工和插削展成加工模型,为数字化齿面展成加工的实际应用提供了理论和方法指导。
(2)数字化齿面展成加工的仿真研究。以虚拟数字化齿面磨削展成加工为例,开展了数字化齿面展成加工的仿真研究。开发了一个数字化齿面加工仿真系统,对磨削模型和求解方法的正确性进行了检查; 对齿面加工连续性、加工精度和加工干涉现象等进行了校验; 为实际加工实验做好了准备。
(3)数字化齿面展成加工齿廓误差综合性分析。研究通过实际齿面测量进行数字化齿面加工齿廓误差分析的方法,建立了齿面加工齿廓误差综合模型,对整个加工齿面的齿廓误差分布形态进行了分析和评定; 并提出了相应的误差值计算算法。研制了数字化齿面加工齿廓误差综合分析软件。
(4)数字化齿面展成加工中的齿廓误差补偿研究。提出了数字化齿面加工齿廓误差预补偿策略,并依据齿面加工齿廓误差分析情况进行误差预测,重构了待加工的虚拟数字化齿面,为后续数字化齿面补偿加工提供了数值依据; 在此基础上,研制了数字化齿面齿廓误差补偿加工软件。
(5)数字化齿面展成加工实验研究。以数字化齿面插削展成加工为例,开展了数字化齿面展成加工实验研究。解决了实际数字化齿面展成加工中的多齿连续啮合
The Digital Gear Tooth Surfaces depicted with dynamics feature differ from the surfaces described on the basis of ideal rigid body in that the former can accurately reflect the elastic and plastic deformation induced by stress and heat in machine operations, thus improve the performance of the gear drive to meet the real requirements of high speed, heavy load, high efficiency and low noise. The research about digital gear tooth surfaces is becoming an important developing aspect for contemporary design & manufacture. It is difficult to generate digital gear tooth surfaces accurately by traditional manufacturing technology. In order to machining digital gear tooth surfaces with high efficiency, great accuracy and remarkable flexibility, researches on generating method and error compensation for digital gear tooth surfaces have been thoroughly carried out in this dissertation. The work covers:
(1) Research on generating method of digital tooth surfaces. Combined with the digitized theory of conjugate surface and the actual technologies for gear machining, the method to manufacture the digital tooth surface is developed. The machining models of gear grinding and shaping for digital gear tooth surfaces are established. The research offers the basic theory and means to manufacture digital gear tooth surfaces practically.
(2) Research on virtual manufacture of digital tooth surfaces with generating method. A simulation generation system like gear grinding is taken as an example to develop, which can verify the model of gear grinding and the generating method of digital tooth surfaces. At the same time, the checkout of continuity, accuracy and interference during the processing can be done. The simulation provides helps to the experiments of gear machining.
(3) Research on error analysis of machining of digital tooth surfaces. The method for extracting machining errors from the information of topography measurements on the real surfaces of physical parts is proposed. The distribution of error on the total tooth surface is analyzed and evaluated. A synthetical error model has been developed, and suitable algorithms have been presented to calculate errors. The software for error analysis is also developed.
(4) Research on error compensation of machining of digital tooth surfaces. A
‘pre-calibration error compensation’strategy is presented. The total compensation error is predicted based on this idea. A virtual digital surface is reconstructed with the prediction. This work offers the numerical value in the subsequent operations. Then, the software for error compensation is developed. (5) Research on experiments of generating machining of digital tooth surfaces. Gear shaping experiments as examples are carried out. Some factual questions such as gear continual meshing are treated with during the experiments. The gear with digitized involute tooth profile and the gear with digitized non-standard tooth profile are slotted successfully. The experiments verify the generating method of digital gear tooth surfaces proposed in this dissertation. (6) Research on slotting experiments of digital tooth surfaces based on error pre-compensation. The Gear with digitized involute tooth profile is taken as example during the experiments. The digital gear tooth surfaces are slotted successfully by the operation with error pre-compensation. The results of accuracy checking of this gear are illustrated and proved the researches mentioned above. The dissertation develops the systematic theory for generating machining of DGTS, hence breaks through the limitation of the traditional approaches based on analytic geometry. The research combining the processing techniques of gear with the technologies of digital measurement, NC machining and computer software, realized the manufacture of gear with high quality. The method presented can be directly applied in the manufacture of the digital design tooth surface and the machining of measuring reconstructed digital surface of the physical parts as well. The research provides theoretical and technical bases for the CAD/CAM technology for manufacturing of digital gear tooth surfaces.
引文
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