汽车驱动桥弧齿锥齿轮齿面偏差网络智能控制理论研究

In the process of automobile drive axle spiral bevel gear machining, the traditional network feedback correction techniques of gear surface deviations can only guarantee the machining precision of tooth surface before heat treatment. There is no way to compensate and correct the tooth surface deviation caused by the heat treatment deformation, which reduced the efficiency and precision of gear lapping. Based on the existing research, in this project, tooth surface deviations before and after heat treatment, and after gear numerical control lapping with same batches will be batched measured firstly. Then, the changed trends of the above two phases will respectively studied by the mathematical statistics theory of self-help method, and the mean surface model of batch tooth surface deviation before and after heat treatment and after gear lapping will be set up. The mathematical model of pre-deformation equivalent tooth surface for gear numerical control cutting before heat treatment will be constructed, and the pre-control compensation mechanism of tooth surface deformation after heat treatment will be established combined with the feedback correction theory for tooth surface deviation. The pre-control modification strategy will be planned through analyzed the tooth contact change rules of gear numerical control lapping. On this basis, the network communication model will be built, the data analysis and processing platform for tooth surface deviation will be developed, and the intelligent control and network feedback correction mechanism of tooth surface deviation will be established. As a result, the pre-control correction of gear numerical control cutting and the pre-control modification of gear numerical control lapping for the tooth surface deviation after heat treatment will realized, which will provide the theoretical basis and the key technical support to improve the tooth surface machining precision and meshing quality of automobile drive axle spiral bevel gear.

在汽车驱动桥弧齿锥齿轮加工中，传统的网络化齿面偏差反馈修正技术，只能保证热处理前的齿面加工精度，对热处理变形后的齿面偏差无法补偿修正，降低了研齿效率及研齿精度。本项目基于已有的研究基础，通过对同批次齿轮热处理前后、数控研齿前后齿面偏差的批量精密检测，基于自助法数理统计理论，分别研究上述两个阶段齿面偏差的变化趋势，建立热前、热后及研齿后的齿面变形均值差曲面模型。通过构建热处理前数控铣齿的预变形等效齿面数学模型，结合齿面偏差反馈修正理论，确立热处理齿面变形的预控补偿机制。通过分析数控研齿的齿面接触变化规律，规划数控研齿的预控修形策略。通过构建网络通信模型，开发齿面偏差数据分析与处理平台，建立齿面偏差的智能控制机制与网络化反馈修正机制，实现热处理齿面偏差的数控铣齿预控修正与数控研齿预控修形，为提高汽车驱动桥弧齿锥齿轮齿面的加工精度和啮合质量，提供理论依据与关键技术支撑。

本项目基于齿面偏差的精确测量理论，以同种齿轮材料、数控铣齿方法与热处理规范的同一批次汽车驱动桥弧齿锥齿轮为对象，研究了弧齿锥齿轮理论齿面的数字化处理和实际齿面偏差的数字化检测理论，构建了齿面偏差计算的数学模型。提出了批量齿面偏差数据的自助法统计分析理论，研究了热处理前后批量齿面偏差的均值差曲面数字化拟合构建方法，确立了热处理变形齿面的预变形等效齿面模型。依据弧齿锥齿轮齿面偏差与铣齿机床调整参数的映射关系，构建了热处理变形齿面的数字化预控等效修正模型，建立了铣齿机床加工参数的数字化预控等效修正机制。提出了基于NURBS 曲面拟合的实测齿面接触分析模型，分析了VHJ调整量与齿面研磨点位置移动的数学关系，建立了热处理后数控研齿的预控修形策略。在此基础上，构建了弧齿锥齿轮齿面偏差网络化集成控制模型，建立了网络化集成控制的运行机制、网络通信机制和信息集成机制，开发了弧齿锥齿轮齿面偏差网络化集成控制系统，并基于等高齿弧齿锥齿轮齿面偏差网络化集成控制应用试验，验证了汽车驱动桥弧齿锥齿轮齿面偏差网络化智能控制理论的相关研究成果在实现齿面热处理变形集成控制方面的正确性和有效性。本项目的研究成果可为同批次汽车驱动桥弧齿锥齿轮的高精度、高效率加工制造提供理论与技术支持。