圆柱齿轮滚齿加工三向Dexel模型仿真与验证

针对基于实体建模技术的滚齿加工仿真问题，开发一种圆柱齿轮滚齿加工三向Dexel模型仿真方法。研究圆柱齿轮滚齿加工的运动学模型。根据滚刀和齿轮毛坯的几何参数创建三角形网格模型，并转换为引擎内的Dexel模型。同时，借助Delaunay三角剖分和Alpha形状重构进行高效的CWE计算和未变形切屑几何仿真。采用斜角切削模型来计算每个时间步上所有啮合节点的力分布。使用利勃海尔LC500滚齿机对所提仿真方法进行了验证，并结合旋转测力计和卡尔曼滤波器来补偿结构动力学，从而进行准确的切削力测量。结果表明：所提方法能够准确预测出沿滚刀刃口离散节点的三维力分布，预测误差(均方根和标准差)在4%～12%之间，且当切削条件变化时，仍然可以准确预测轴向和横向的切削力，有助于进一步提高滚齿加工仿真的效率与精度。

Three-Dimensional Dexel Model Simulation and Verification of Cylindrical Gear Hobbing

Aiming at the problem of hobbing simulation based on solid modeling technology,a three-dimensional Dexel model simulation method of cylindrical gear hobbing was developed.The kinematics model of cylindrical gear hobbing was studied.According to the geometric parameters of hob and gear blank,the triangular mesh model was created and transformed into the Dexel model in the engine.At the same time,efficient CWE calculation and geometric simulation of undeformed chips were carried out by Delaunay triangulation and Alpha shape reconstruction.The bevel cutting model was used to calculate the force distribution of all meshing nodes at each time step.Finally,Liebherr LC500 gear hobbing machine was used to verify the proposed simulation method,and the rotating dynamometer and Kalman filter were combined to compensate the structural dynamics,so as to measure the cutting force accurately.The results show that the proposed method can be used to accurately predict the three-dimensional force distribution of discrete nodes along the edge of hobbing,and the prediction error (root mean square and standard deviation) is between 4% ~ 12%; when the cutting conditions change,the axial and lateral cutting forces can still be accurately predicted,which is helpful to further improve the efficiency and accuracy of hobbing simulation.