Modelling, simulation and compensation of thermal effects by hobbing gears

滚齿齿轮热效应的建模、仿真和补偿

• 批准号: 178975135
• 负责人: Professor Dr.-Ing. Thorsten Halle
• 金额: --
• 依托单位: Institut für Werkstoff- und Fügetechnik (IWF)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2010
• 资助国家: 德国
• 起止时间: 2009-12-31 至 2018-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/178975135?language=en
• 关键词: Modelling; simulation; compensation; thermal; effects

Within the research project of the priority program 1480, the heat introduction into hobbed gears is investigated. The final aim is to enable the conditions for hobbing large gears without coolant. Due to the high heat quantity which is caused by dry hobbing the gear quality is deteriorating. For this reason the industry is using the nonproductive wet hobbing process. Compared to dry cutting, the coolant usage implies detrimental effects to environment and the manufacturing costs. To adopt the dry hobbing process for large gears, it is necessary to investigate the effect of the heat flux on the workpiece. Hobbing is oftentimes the last step in the process chain for large gears. In this step deviations in form and position could accrue and cannot be compensated anymore. For this reason special attention is needed herein.In the hobbing process, there are multiple gear teeths in contact. During this step, the chip geometry is different on every single tooth. This makes it difficult to carry out single tooth contact analysis on the workpiece. Thus an analogy trail is developed which enable the analysis of the single heat sources and simulation with FEM. In the second period of the project the results of the first period should be transferred to real hobbing. The experimental investigations are focused on thermal conditions in hobbing and its effect on the gear quality. The experimental investigations are focused on the thermal conditions in hobbing and its effect on the gear quality. At this platinum thermometer and an infrared camera are used. Furthermore the deformation of the gear is simulated by FEM to generalize the results. Afterward the gained knowledge will be transformed to a large gear in wind power industry. The experimental results of the IFQ serve to verify the simulation of the IWW.The method of FEM is used to describe the heat conduction and to calculate the local and global temperature gradient. The connection of the technological parameters and the transferability of changing parameters are assured by an analytical and semi-analytical model. Based on a verified and validated substitution model, which is created in the first period of the project, a transfer to real hobbing will take place. Thereby a calculation of the thermal deformation will be possible. This leads to the third project period where possibilities of compensations are identified.By the use of the simulated gear deformation, it is possible to estimate the feasibility of the process. Consequently different compensation can be used to avoid the thermal deviations on large gears.

在优先计划1480的研究项目中，对滚齿齿轮的热引入进行了研究。最后的目的是使条件滚大齿轮没有冷却液。由于干式滚齿产生的热量很高，齿轮质量不断恶化。出于这个原因，工业界正在使用非生产性的湿法滚齿工艺。与干切削相比，冷却剂的使用意味着对环境和制造成本的不利影响。采用干式滚齿工艺加工大型齿轮时，需要研究热负荷对工件的影响。滚齿通常是大型齿轮加工链中的最后一步。在这一步中，形式和位置上的偏差可能会增加，并且不能再被补偿。因此，这里需要特别注意。在滚齿过程中，有多个齿轮齿接触。在此步骤中，每个单个齿上的切屑几何形状都不同。这使得难以对工件进行单齿接触分析。因此，开发了一种模拟试验，使单一热源的分析和有限元模拟。在项目的第二阶段，第一阶段的成果应转化为真实的滚齿。实验研究的重点是滚齿过程中的热条件及其对齿轮质量的影响。实验研究的重点是滚齿加工中的热条件及其对齿轮质量的影响。在这个铂温度计和红外摄像机使用。并对齿轮的变形进行了有限元模拟，以推广计算结果。之后，所获得的知识将转化为风力发电行业的大型齿轮。IFQ的实验结果验证了IWW的模拟。有限元方法用于描述热传导，并计算局部和全局温度梯度。工艺参数之间的联系和变化参数的可传递性由解析和半解析模型来保证。基于在项目第一阶段创建的经过验证和确认的替代模型，将转移到真实的滚齿。因此，热变形的计算将是可能的。这导致了第三个项目周期，在此期间，补偿的可能性被确定。通过使用模拟齿轮变形，可以估计该过程的可行性。因此，可以使用不同的补偿来避免大齿轮上的热偏差。