一种圆柱型车齿刀的安装模型及无干涉设计方法

An Installation Model and Interference-free Design Method for Cylindrical Power Skiving Tools

车齿加工由于其兼具滚齿的连续切削运动和插齿的端面切削模式,对于内齿结构和双联齿轮结构具有卓越的加工性能。相较于圆锥型车齿刀由于前刀面刃磨引发切削刃改变,圆柱形车齿刀可以确保刀具全生命周期内的无理论误差刃型,但是其零度后角更易于造成加工过程中刀齿侧面与工件齿槽面的干涉。然而目前国际主流圆柱型车齿刀的安装模型都封装在计算机辅助制造(Computer aided manufacturing,CAM)系统中,限制了国内圆柱型车齿刀的设计开展与推广应用。因此,研究圆柱型车齿刀偏位安装模型形成无干涉设计对于打破国外技术垄断至关重要。针对通用的5轴车齿机配置,提出了一种圆柱型车齿刀的安装模型,并给出了从安装模型参数确定、切削刃求解和切削仿真、刀齿切削干涉判定的完整计算流程,进而形成圆柱型车齿刀的无干涉设计方法,最终通过针对内齿圈的设计和加工仿真验证了该方法的有效性。

Power skiving provides excellent machining performance for inner gear structure and dual-link gear structure since it has both the continuous cutting motion of hobbing and the end face cutting mode of gear shaping.Compared with the conical gear cutter,of which the rake flank shaperen changes its cutting edge curve,the cylindrical skiving tools maintain the cutting edge curve without theoretical error during its whole life cycle.However,the zero back angle of cylindrical skiving tools is more likely to cause interferences between the cutting teeth flank and the gear slot surface during the machining process.Nowadays,the installation model of the international mainstream cylindrical skiving tools is encapsulated in Computer Aided Manufacturing(CAM)system,which limits the design and application of domestic cylindrical skiving cutter.Accordingly,study on the installation model and interference-free design method for power skiving tools is significant to break the foreign technology monopoly.According to the configuration of general purpose 5-axis power skiving machine tools,a cylindrical skiving cutter installation model is proposed,and the complete calculation process including determination of the installation model's parameters,computation of the cutting edge and simulation of the cutting edge,and judgement of the cutter teeth interference is given,which form the non-interference design method of the cylindrical skiving tools.Finally,a design and machining simulation of an internal gear validate the effectiveness of the proposed method.