具齒面修整之齒輪刮削研究

Abstract

齒輪齒面修整亦稱為齒輪隆齒，能夠大幅地提高齒輪的性能；齒輪刮削是具備高效率的齒輪精加工法，其中橫向式刮齒與直進式刮齒是齒輪刮削的基本形式，能夠以高效率的方式完成齒輪齒面修整。本論文針對此兩種形式之刮齒方法進行研究，探討其對於齒輪之隆齒的影響。論文中研究了在橫向刮齒製程中的機器設定參數與刀具裝備誤差對齒面修整的影響，並以實驗設計法對製程中各項參數進行最佳化研究，提高了齒輪的傳動性能。以本研究中的範例說明，在相同條件下的傳動誤差可以得到相當程度的改善 對於直進式刮齒，本論文提出一設計最佳化方法，針對具隆齒的齒輪調整直進式刮齒刀的齒面修形，藉由降低刮齒刀之輪磨齒面與理論齒面之間的拓樸誤差，可進一步改善工件齒輪齒面誤差；本研究亦分析了直進式刮齒的切削路徑，針對刮齒刀齒面插槽設計參數進行最佳化設計，能夠有效地提高刮齒效率，使其切削比(cutting-down ratio)可得到相當程度的改善。

Gear tooth modification, also called gear tooth crowning, can cause great improvement of gear performance. Gear shaving is one of the most efficient and economical process for gear finishing after the rough cuttings of hobbing or shaping, in which transverse shaving and plunge shaving are the most widely adopted methods. Through gear shaving, tooth crowning can be achieved very efficiently. This dissertation has investigated gear tooth crowning induced by transverse and plunge gear shaving. For transverse gear shaving, the influences of machine setting parameters and cutter assembly errors have been observed. Design optimization for robustness of gear transmission error has also been accomplished, in which the transmission error has been greatly improved. For plunge gear shaving, in order to manufacture gears with tooth crowning, a method of design optimization is proposed to reduce the topographic error between the theoretical and the ground shaving cutter tooth surfaces, in which the analytical description of the gear with tooth crowning is constructed, and then the grinding wheel profile is parameterized and optimized. The cutting trace of plunge shaving cutter has also been analyzed by optimizing the arrangement of cutter serration, so that the cutting-down ratio can be reduced and therefore the cutting efficiency can be improved.