Simulation-Based Prediction of Sub-Surface Properties in Skive-Hobbing

在滑动滚刀中，齿面由几个刀具啮合形成，每个啮合都有单独的啮合条件。根据这些接合条件，不同的热机械载荷被施加到齿侧。以同样的方式产生工件的地下特性不同，例如残余应力的大小和方向。最后，工件的疲劳强度受残余应力局部分布的影响。测量过程引起的残余应力分布是一个复杂的过程，如果可能的话，会导致耗时的计划和测量行动。由于这个原因，本项目建议建立过程引起的残余应力模型，相对于它们在齿面上的位置。这是通过建立一个预测齿面残余应力及其分布的组合模型来实现的。该模型由基于参考试验的经验过程模型、过程运动学仿真和几何啮合条件计算组成。该模型能够根据所选的滑滚加工工艺参数对残余应力进行预测。在未来，该模型将应用于规划和优化切割和测量过程以及刀具的开发。

In skive hobbing the tooth flank is shaped by several tool engagements, each characterized by individual engagement conditions. Depending on these engagement conditions different thermomechanical loads are applied to the tooth flank. In the same way the resulting subsurface properties of the workpiece differ, e.g. magnitude and direction of residual stress. Finally the fatigue strength of the workpiece is influenced by the local distribution of residual stress. The measurement of process induced residual stress distribution is a complex procedure which, if possible at all, results in time-consuming planning and measurement actions. For this reason this project proposal suggests to model process induced residual stresses with respect to their position on the tooth flank. This is achieved by building up a combined model predicting the residual stress and its distribution on the tooth flank. The model consists of an empirical process model based on reference trials, a simulation of the process-kinematics and a calculation of the geometrical engagement conditions. The model enables a forecast of the residual stress with respect to the chosen process parameters of skive hobbing. In the future the model will be applied to plan and optimize cutting and measurement processes as well as for the development of cutting tools.