中文摘要：

高速干切滚齿工艺是一种发展迅速的齿轮绿色制造工艺,但干切条件下刀具容易磨损,特别是滚切工艺材料去除过程的复杂性,导致切削刃的载荷分布不均,刀具局部磨损严重,影响该工艺的经济性。面向齿轮滚切工艺的材料去除过程,提出了基于三维切屑的切削刃载荷计算方法,根据不同切屑几何获得相应单刃切削载荷分布状态及批量加工中切削刃的平均载荷分布状态。通过仿真计算和滚切试验案例,对比分析了切削刃载荷分布与切削刃实际磨损的关系,发现侧刃和顶刃过度圆弧处切削载荷最大,切削刃磨损也最严重,验证了该方法的有效性。最后,基于该方法分析了滚切进给方向和进给量对切削刃载荷分布的影响,其结论对于生产实践中控制刀具磨损具有指导意义。

英文摘要：

High-speed dry hob cutting technology is rapidly developing as a green manufacturing technology for gear. But the cutting tool would wear quickly in condition of dry cutting. Especially, non-uniform load distribution on the cutting edge, which is induced by the complexity of the material removal process during gear hobbing, causes serious localized wear, and it affects the economy of this technology. This article is oriented to the material removal process of gear hobbing process. And calculation method of the load distribution on the cutting edge is proposed based on the 3D chip geometry. By the proposed method, the load distribution on single cutting edge is acquired with corresponding chip geometry, and the general load distribution on cutting edge in the actual batch processing is formed. Then a case of simulation and high-speed hobbing experiment is proposed. By comparative analysis of the relationship between load distribution and wear of the cutting edge, the effectiveness of this method is validated. It is found that the cutting load on the fillet arc between the side edge and top edge is maximal and the cutting edge wear is also the most serious. Finally, the influence of feed direction and feed rate on cutting load distribution is analyzed based on the proposed method. The corresponding conclusion is of guiding significance for the control of tool wear in production practice.