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

在刮削滚齿中，齿面是由几个刀具啮合形成的，每个刀具啮合的特征在于单独的啮合条件。根据这些啮合条件，不同的热机械载荷施加到齿面上。同样，工件的表面下特性也不同，例如残余应力的大小和方向。最后，工件的疲劳强度受局部残余应力分布的影响。测量工艺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。因此，本项目建议根据其在齿面上的位置对过程引起的残余应力进行建模。这是通过建立一个组合模型预测残余应力及其分布的齿面。该模型包括基于参考试验的经验过程模型、过程运动学模拟和几何啮合条件计算。该模型能够预测残余应力相对于选定的工艺参数刮削滚齿。在未来，该模型将被应用于计划和优化切割和测量过程以及切割工具的开发。

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.