中文摘要：

齿轮滚切工艺是应用最广泛的齿部成形加工工艺,高速干切工艺的出现和逐步成熟为齿轮滚切实现绿色环保加工以及高效自动化生产提供了技术条件。但由于高速干切工艺切削速度高且缺少切削油/液的冷却润滑,因而工艺参数对机床热变形误差、刀具寿命和工件质量等影响很大,需要开展深入研究。以自动化加工效率、齿轮单件成本为目标,工件材料、刀具涂层以及切削速度、进给量和滚刀顶刃最大切屑厚度等因素为变量,建立一种齿轮高速干式滚切工艺参数优化模型。通过数据分析和试验验证,基于工件材料的抗拉强度,得出齿轮高速干切滚齿工艺切削速度和滚刀顶刃最大切屑厚度推荐值;同时,为实现模型在齿轮自动化生产线上的应用,建立了高速干切滚齿工艺参数在机自适应优化修正模型,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。该系统在某轿车齿轮自动生产线的生产实践中得到应用,取得了良好的效果。

英文摘要：

Gear hobbing process is the most widely used forming process of gear teeth. The development of high-speed dry cutting technology provides a solution for realizing green, efficient and automated gear production. Since the lack of cutting oil in high-speed dry hobbing, the thermal deformation errors of machine tool, the hob life and the quality of workpiece are sensitive to the process parameters, especially the cutting speed and the maximum chip thickness. A hobbing parameter optimization model with hobbing efficiency and cost of single gear as objectives is established, in which the workpiece material, coating of hob, cutting speed, feed rate and maximum chip thickness are considered as variables. With simulation and experiments, the relationships between the tensile strength of materials and the recommended value of cutting speed and the maximum chip thickness respectively in high-speed dry gear hobbing process are established. For the application in automated production line, an online adaptive model for hobbing parameters optimization is proposed, and an application system is also developed based on SINUMERIK 840D system. The application in a gear automated production line for automobile gear box has shown the model and the system is practical.