Study on the Cutting Time of the Hypoid Gear Tooth Flank
| Autor: | Szu-Hung Chen, 陳思宏 |
|---|---|
| Rok vydání: | 2014 |
| Druh dokumentu: | 學位論文 ; thesis |
| Popis: | 103 According to the relationship of transformation matrices among the universal face-milling methods by Klinglnberg and Gleason, this study proposes a cutting simulation method for face-milling that involves using SolidWorks application programming interface (API) functions. The proposed cutting simulation method can be used to simulate the face-milling cutting method by Gleason. The machine and cutting settings were verified by performing simulations, and the feed-rate was adjusted to obtain a constant cutting torque throughout the process to decrease the cycle time based on the simulation results. For mass production, the gear fixture can be manufactured according to the simulated 3D model to prevent the cutter from striking the fixture throughout the process. The proposed cutting simulation method can reduce the time involved in designing and manufacturing new hypoid gears. Consequently, the cost of product development can be reduced and the efficiency can be increased simultaneously. The cutting simulation method can also be used to analyze the Gleason cutting settings before cutting is performed. This dissertation proposes solutions for three research problems. (a) A mathematical model of a universal face-milling hypoid-gear generator was created to perform the cutting simulations. Mathematical models of Gleason and Klinglnberg hypoid-gear generators were developed to convert the machine settings to a universal face-milling coordinate system to analyze the machine and cutting settings. The mathematical models of six-axis and five-axis computer numerical control (CNC) machines were developed for manufacturing a gear set based on existing CNC machines. The relationships among the machine settings can be determined by comparing the components of the transformed matrix in the universal face-milling coordinate system with those by Klinglnberg and Gleason, as well the six- and five-axis CNC machines. The relative position between the head cutter and workpiece in the universal face-milling coordinate system can be determined according to the corresponding machine settings by Klinglnberg and Gleason. A cutting simulation was performed to verify the machine settings and determine the cutting settings derived from the simulation results. Finally, the G-codes were obtained to manufacture a gear set on the six-axis or five-axis CNC machines. (b) Using SolidWorks API functions, we developed computer software to simulate a hypoid-gear cutting generator based on a universal cradle-type hypoid generator. The software can simulate existing cutting methods. The relative position between the head cutter and workpiece was verified using the software to prevent the cutter, workpiece, and machine unit from colliding throughout the process. After the cutting simulation, the overlap volumes and corresponding generation positions are recorded and fitted as polynomial curves for planning the feed-rates throughout the cutting process. The geometry of a fixture that would not be struck by the cutter can thus be determined. A fixture with high rigidity can be manufactured according to the simulated 3D model. The machine settings, cutting settings, G-codes, and fixture can be verified using the developed software to reduce the costs and risks involved in manufacturing the gear by using general six-axis and five-axis machines. A solid model of finished hypoid gear can be used to verify the machine settings and for further finite element method analysis. (c) The material-removal polynomial curve can be applied to analyze and adjust the cutting settings of the Gleason model to reduce the machining time at an identical maximal cutting torque. A hypoid-gear cutting plan was developed to implement the constant material removal rate (CMRR) concept by varying the feed rate and cradle roll velocity (CRV) to retain the cutting torque within a certain range throughout the cutting process, thereby reducing the impact force at the cutter-engage point. The proposed CMRR process was experimentally verified using a six-axis CNC hypoid-gear generator by measuring the electrical current of the cutter spindle motor, which is proportional to the cutting torque. |
| Databáze: | Networked Digital Library of Theses & Dissertations |
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