车齿工艺主切削力预测与工艺参数优化

Prediction of main cutting force and optimization of process parameter in gear skiving

  • 摘要: 以车齿工艺为研究对象,研究其切削力的变化规律,并对切削力进行预测优化,提出一种优化工艺的参数控制方法。首先,根据车齿工艺运动学原理,建立了工件齿轮和车齿刀具实体模型,通过仿真实验得到了单刀齿切削过程中切削力的响应数据;其次,采用响应曲面法建立了主切削力预测模型,并分析了切削速度、进给量和刀具与工件间轴交角三项工艺参数对主切削力的影响规律;最后,以主切削力为约束条件,以最高加工效率为目标,基于遗传算法对工艺参数进行优化。结果表明:对主切削力影响最大的单工艺参数与多元工艺参数分别为进给量与进给量–轴交角,并且优化预测值与仿真结果之间误差在合理范围内,验证了预测模型的有效性。研究方法与结果为提高车齿工艺加工质量与刀具寿命等提供了重要参考。

     

    Abstract: Taking the gear skiving process as the object, the changing law of cutting force is studied, and predictive optimization of cutting forces, and a parameter control method for optimizing the process is proposed. Firstly, according to the kinematic theory of gear skiving, the solid models of workpiece and cutter are constructed, and the response data of cutting force in the process of single-tooth cutting are obtained through simulation experiments; secondly, the main cutting force prediction model is established based on multiple linear regression method, and the influence law of three process parameters on the main cutting force is analyzed: cutting speed, feed amount and axis intersection angle between tool and workpiece; finally, the main cutting force is used as Finally, the process parameters were optimized based on genetic algorithm with the main cutting force as the constraint condition and the highest machining efficiency as the target. The results show that the single and multiple process parameters with the greatest influence on the main cutting force are the feed and feed-axis intersection angle, respectively, and the error between the optimized predicted value and the simulation result is within a reasonable range, which verifies the validity of the prediction model. The research method and results provide an important reference for improving the machining quality and tool life of gear turning process.

     

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