Reaseach for Development of Intelligent Finish Gear Rolling System by Screw-Shaped Tool

采用标准齿形螺旋刀具对标准齿形直齿轮和压力角误差进行了滚齿实验。压力角误差设置为0.12度。使用渐开线磨床进行加工。在轧制前后仔细检查工件的齿形和轧制量的分布。随着车辆量的增加，工件的压力角误差减小，齿形呈凹形。为了开发螺旋形刀具智能滚齿系统，首先在上述实验结果的基础上建立了滚齿率数据库；其次，提出了一种简单的计算方法来预测工件轧制后的齿形。第三，将数据库与简单的计算方法相结合，开发了一套修正齿形螺杆刀具设计专家系统。利用该专家系统设计并实际生产了两种螺纹刀具的修形齿形。新刀具改善了压力角误差，抑制了轧制齿形产生凹的趋势。验证了所提计算方法的有效性和实用性。利用商业有限元软件ABAQUS建立了理论上确定轧制率的数值模拟模型。利用该模型对二维平面应变条件下轧制直齿轮的齿形进行了分析。将理论齿形与实验齿形进行了比较，证明了该变形模型可用于计算轧制坯料量以及工件和刀具在轧制过程中的整体变形。

Finish gear rolling experiments of spur gears with a standard tooth profile and with the pressure angle errors are done using the screw-shaped tool with a standard tooth profile. The values of pressure angle error are set to 0.12 degree. The involute grinder is used to produce the work. The tooth profiles of the work and the distribution of the amount of the stock rolled are carefully examined before and after rolling. As the amount of the rolling stock increases, the pressure angle errors of the works lessen, while the tooth profile becomes concave. In order to develop the intelligent finish gear rolling system by screw-shaped tool, firstly the database of the rate of stock rolled are constructed based on the experimental results obtained above. Secondly, a simple calculation method is also proposed to predict the tooth profile of the work after rolling. Thirdly, an expert systen to design the screw-shped tool with the modified tooth profile is developed by combining the database and the simple calculation method. Two modified tooth profile of the screw-shaped tool are designed using this expert systm and actually produced. The pressure angle errors are improved and the tendency to produce the concave rolled tooth profiles are suppressed by the new tools. The validity and the usefulness of the proposed calculation method are confirmed. The nunerical simulation model using the FEM commnercial package ABAQUS is made to decide the rate of the stock rolled theoretically. The tooth profiles of the rolled spur gears are analyzed by this model under the two dimensional plane-strain condition. The theoretical tooth profiles are compared with the experimantally rolled tooth profiles and this deformation model is Proved to be usefhl to calculate the amount of the stock rolled and the ehstic deformation of the work and the tool during rolling.