齿轮绿色高速干切滚齿工艺性能优化基础理论与实验研究

The innovation of green process and equipment is one of the key solutions for mechanical industry to implement the strategy of green manufacturing and energy saving & emission reduction. As a typical green metal removal technology, high speed dry hobbing process is high-effeciency and low-cost while eliminates the pollution of oil mist in shop floor and environment contamintation caused by waste cutting oil.At present, comparing the domestic technology of high speed dry hobbing process with that of developed countries there being a huge gap on process reliability, thermal stability and life of hobs. The short of indepth research on basic theories of high speed dry hobbing process is the primary reason.Based on the previously developed high speed dry hobbing machine and hobs, the basic theories and experiment researches will be put into effect in this project.The following aspects will be included: 1) 3D shaping model of interupted cutting process by multi-cutting-edge will be established. In this research a tool for analysing the shaping process of gear hobbing and the geometircal figuration mechanisim of chips as well as enveloping corrugation of tooth flank on workpiece will be provided. 2) The mechanisim of cutting heat generation and thermal transmission in high speed dry hobbing process will be revealed in order to optimally control temperature rise in cutting zoon. 3) The damage behavior and failure mechanisim of cutting edge of hob under high speed dry cutting condition will be illuminated, which would provide theoretical basis for extending hob's life and enhancing processing stability. 4) Experiment equation about the economic life of hob will be established based on perfomance test. The outcome of this project will support parameter optimize for high speed dry hobbig process.

绿色工艺与装备创新是机械工业实施绿色制造、节能减排战略的关键途径之一。高速干切滚齿工艺消除了滚齿加工过程中的切削油雾、废油环境污染，同时具有高能效、低成本等特点，是一种典型的绿色切削新工艺。目前国内高速干切滚齿工艺在工艺可靠性、热稳定性、滚刀寿命等方面与发达国家差距很大，根本原因在于高速干切滚齿工艺基础理论的深入研究非常匮乏。本项目将在前期高速干切滚刀及机床研制基础上，深入开展高速干切滚齿工艺基础理论和实验研究，建立高速干切滚齿工艺多刃断续空间三维成形模型，为滚齿工艺成形过程、切屑几何成形机理、工件包络波纹形貌等工艺几何分析提供工具；揭示高速干切滚齿工艺切削热产生、传递机理，为切屑载热量优化及切削区温升控制提供理论基础；阐明高速干切条件下滚刀切削刃损伤行为和失效机理，为滚刀寿命延长和工艺稳定性增强提供理论基础；通过工艺性能实验，建立滚刀经济使用寿命经验公式，为高速干切工艺参数优化提供支持。

在国家自然科学基金项目资助下，项目组在前期高速干切滚刀及机床研制基础上，深入开展了绿色高速干切滚齿工艺性能优化基础理论与实验研究，建立了高速干切滚齿工艺关键基础理论体系，填补国内在这方面的空白，主要研究成果为：（1）建立了高速干切滚齿工艺多刃断续切削空间三维成形模型、滚齿动态切削力模型、齿面包络误差模型，并开发了数字可视化支持工具；（2）揭示了高速干切滚齿工艺切削热产生、传递机理，建立了高速干切滚齿工艺切削热传递过程模型；（3）建立了高速干切滚齿工艺切屑载热量和载热能力、高速干切滚齿机床、切削空间、主轴系统等的热能累积与热平衡优化调控模型；（4）提出了基于三维切屑的滚刀切削刃载荷计算方法，揭示了强热力耦合作用下高速干切滚刀切削刃的损伤行为和失效机理，建立了切屑流形变挤压损伤评价指标及多参量修正抑制方法；（5）通过飞刀铣齿实验和高速干切滚齿工艺性能实验，建立了滚刀经济使用寿命经验公式；（6）建立了高速干切滚齿工艺参数优化模型，并基于西门子840D数控系统开发了高速干切滚齿工艺参数优化支持系统。上述研究成果为高速干切滚齿工艺装备的研制及其工艺性能优化提供理论基础。