CN111090930B - Solidworks-based geometric model construction method for cutting scraps - Google Patents
Solidworks-based geometric model construction method for cutting scraps Download PDFInfo
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Abstract
The invention discloses a method for constructing a cutting chip geometric model based on Solidworks in the field of tooth cutting machining, which is mainly characterized in that a simulation system is used for creating a workpiece geometric entity and a cutting edge model of a tooth cutting knife, according to a motion relation and a position relation between the tooth cutting knife and a workpiece, an edge scan model formed by cutting edges on the tooth of the tooth cutting knife on a workpiece coordinate system relative to the workpiece is constructed, then a workpiece blank is combined with the edge scan, an undeformed chip and a new instant tooth slot are formed by Boolean operation between the edge scan and the instant tooth slot geometric entity, and after the simulation is finished, an undeformed three-dimensional chip geometric model of a certain tooth of the tooth cutting knife is output.
Description
Technical Field
The invention belongs to the field of tooth cutting machining, and particularly relates to a method for constructing a geometric model of cutting scraps based on Solidworks.
Background
The gear cutting technology (called as a gear cutting technology by foreign science or Power turning technology by domestic partial workers) is a new technology for actually realizing gear machining in the 21 st century, can solve the difficult problem of machining gears with special structures such as thin walls, non-through inner helical gear sleeves and the like of an automatic transmission of an automobile, and has the advantages of high efficiency, high precision, dry cutting and the like.
(the following sections are foreign study cases)
In the 21 st century, research on Scudding technology by German Wera company has not been interrupted, spline rolling and inserting machine tools are introduced in 2006, and automatic gearbox tooth sleeve parts are processed in 2009 by matching enterprises of automatic gearbox parts in China. The company adopts a mode of machine tool and cutter key exchange engineering to strictly keep the cutter technology secret. From the actual use condition of the machine tool, the technology does not reach the expected effect, the cutter can meet the processing requirement only by repeated trial cutting and adjustment according to the workpiece provided by the user, and the processing precision does not reach the expected value. From this, it can be determined that the Wera company has not formed a mature theoretical system in terms of tool design.
In 2013, during the thirteenth chinese international machine tool exhibition, gleason showed work pieces and simulated machining videos obtained by Power Skiving technology machining, no tools and machine tool objects. In 2015, during the fourteenth chinese international machine tool development period, gleason developed a Power cutting tool, which still adopted the design theory of the gear shaper cutter from the view of the on-site tool design schematic. During the fifteenth chinese international machine tool show period 2017, gleason corporation has shown a Power clamping machine tool and a polytype tool. From the exhibition site and literature, gleason corporation has developed involute straight tooth cutters and helical tooth cutters, but the straight tooth cutters have interference in processing, and the sharpening range is smaller; the processing quality of tooth surfaces at two sides of the helical tooth cutter is inconsistent.
During the fifteenth international machine tool exhibition in 2017, the metal cutting tool provider Sandvik corporation from sweden exhibited the Power Skiving tool entity and integrated software system. From the field display, the cutter still adopts the traditional gear cutter design method, but the software system integrating cutting simulation, cutter design and process parameter optimization is relatively strong in competitiveness, but no engineering application case exists at present, and a considerable distance is provided from practical application.
Disclosure of Invention
In order to solve the problems, the invention aims to improve the precision of gears and tooth shapes to realize high simulation.
In order to achieve the above object, the technical scheme of the present invention is as follows: a Solidworks-based cutting chip geometric model construction method comprises the steps of creating a workpiece geometric entity by using a simulation system, constructing a cutting edge model of a tooth scraping knife, constructing a cutting edge sweeping model formed by cutting edges on cutter teeth of the tooth scraping knife under a workpiece coordinate system relative to a workpiece according to a motion relation and a position relation between the tooth scraping knife and the workpiece, combining a workpiece blank with the cutting edge sweeping, forming undeformed chips and new instant tooth grooves by Boolean operation between the cutting edge sweeping and the instant tooth groove geometric entity, and outputting the undeformed three-dimensional cutting chip geometric model of a certain cutter tooth of the tooth scraping knife in the cutting process after simulation is finished.
Technical principle: the technical basis of the technical proposal is that the basic shape of the undeformed chip determines the basic shape and the chip removal condition of the chip to a certain extent and influences the whole tooth cutting machining process and the machining quality. The technology utilizes the undeformed three-dimensional chips formed by simulation, and lays a foundation for the research of cutting mechanism such as dynamic cutting force of tooth cutting machining, abrasion of a tooth cutting knife and the like.
After the scheme is adopted, the following beneficial effects are realized: 1. compared with the prior art of using three-dimensional finite element software Abaqus to build a powerful tooth-cutting model by using the foreign scholars Antoniadis and the like, the technical scheme not only reproduces the direction of chip flow, but also improves the precision of gears and tooth shapes through the precision of instantaneous tooth grooves.
2. Compared with the domestic Liu Bing et al, which establishes a gear cutter geometric model based on a gear meshing principle, preliminary simulation data is obtained through the DEFORM-3D software, and the technical scheme combines the motion relationship and the position relationship between the gear cutting knife and the workpiece, so that the high simulation after substituting parameters is realized, and the process from the exploring stage to the realizing stage of gear processing is realized.
3. Compared with Yang Tangjun et al, geometric simulation is carried out on the cutting process of the equivalent rake angle tooth scraper based on Vericut simulation software, in the technical scheme, the simulation result is fit with reality through the edge sweeping model formed by the cutting edge on the tooth of the tooth scraper relative to the workpiece.
Further, the method comprises the following steps;
s1, inputting parameters, respectively establishing a workpiece coordinate system, a workpiece auxiliary coordinate system, a tool coordinate system and a tool auxiliary coordinate system, establishing a workpiece tooth surface model on the basis of the workpiece coordinate system, and simultaneously bringing vector coordinates to limit a center distance, an intersection angle and an initial rotation angle;
s2, a cutting edge model is established, a conjugate surface of a theoretical tooth surface of a workpiece is used as a reference surface, then a plane or other regular curved surfaces are adopted to meet the conjugate surface to obtain an intersection line, and the intersection line is used as a cutting edge of the tooth scraper;
s3, converting a cutting edge and a workpiece coordinate system by the edge scanning model, and taking time parameters to divide the edge scanning model into a partial cutting-in state, a complete cutting-in state and a cutting-out state so as to form a continuous curved surface;
s4, generating an instantaneous tooth slot, and carrying out Boolean operation on the blade sweeping surface and the geometrical entity of the instantaneous tooth slot;
s5, outputting, and generating three-dimensional undeformed chips and instantaneous tooth grooves.
The beneficial effects are that: 1. the three-dimensional simulation method based on the solid modeling is provided, so that not only can an instant tooth socket with high similarity with the actual tooth cutting machining be obtained, but also an undeformed three-dimensional chip close to the actual tooth cutting machining can be obtained, and a foundation is laid for researching the cutting mechanism of the tooth cutting machining.
2. With respect to other modeling solutions (cf. The background and the advantageous effects of claim 1), the precision improvement of the present solution with respect to modeling is that the object auxiliary coordinate system (hereinafter S P ) With the auxiliary coordinate system of the tool (hereinafter S 0 ) The space position between the two coordinate systems is fixed and does not change along with time, and the two coordinate systems are mutually used as static reference objects, so that the accuracy of processing the relative positions of the workpiece and the cutter in a moving state is improved.
3. Compared with the prior art with a static reference coordinate system, the method and the device introduce the center distance, the axiality angle and the initial rotation angle as parameters, limit and express the motion track of the tool or the workpiece, materialize the fuzzy track and improve the accuracy of the generated image and the definition of the generated image.
Further, in the step S1, the method for establishing the coordinate system is as follows, and the object coordinate system is S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Wherein o 1 Represent S 1 Origin of coordinates of coordinate system, x 1 Axis, y 1 Axis, z 1 The unit vectors of the axes are i respectively 1 ,j 1 ,k 1 ；S p (o p ,x p ,y p ,z p ) Is S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Wherein o is p Represent S p Origin of coordinates of coordinate system, x p Axis, y p Axis, z p The unit vectors of the axes are i respectively p ,j p ,k p ；
The coordinate system of the tool is S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Wherein o 2 Represent S 2 Origin of coordinates of coordinate system, x 2 Axis, y 2 Axis, z 2 The unit vectors of the axes are i respectively 2 ,j 2 ,k 2 ；；S 0 (o, x, y, z) is S 2 (o 2 ,x 2 ,y 2 ,z 2 ) O represents S 0 The coordinate origin of the coordinate system, and the unit vectors of the x axis, the y axis and the z axis are i, j and k respectively;
the tooth surface model of the workpiece is then in a coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Establishing a tool model in a coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Establishing a coordinate system S p And a coordinate system S 0 Is fixed in space position;
finally, the following parameters are established with reference to a coordinate system: (1) the center distance a is the vertical distance between the axis of the tool and the axis of the workpiece; (2) the intersection angle gamma is the included angle between the axis of the tool and the axis of the workpiece; (3) phi (phi) 1 Is the object coordinate system S 1 An angle with which the workpiece rotates relative to the initial position; (4) l is the object coordinate system S 1 Relative to auxiliary coordinates S p Along a workpieceAxial z p Distance of axial forward movement, (5) phi 2 Refers to a tool coordinate system S 2 With the angle of rotation of the tool relative to the initial position.
Further, the matrix change condition for the cutting teeth is that T=T 20 ·T op ·T p1
Wherein T is 20 From tool coordinate system S 2 To an auxiliary coordinate system S 0 Transform matrix, T op Finger slave auxiliary coordinate system S 0 To an auxiliary coordinate system S p Transform matrix, T p1 Finger slave auxiliary coordinate system S p To the object coordinate system S 1 Is used for the transformation matrix of the (a).
Further, in step S3, constructing a path of tooth processing according to a conjugate principle to construct a blade sweep, the construction method comprising a) or b) as follows;
a) Coordinate system S of tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) Is converted into a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Or (b)
b) Coordinate system S of the workpiece 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is converted into a tool coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 )。
Further, in b) the time parameter t, D is taken in 1 Representing t 1 Cutting edge D corresponding to moment i Representation [ t ] 1 ,t 2 ]At a certain time t in i Corresponding toCutting edge D of (2) n Representing t 2 Cutting edge corresponding to moment, wherein reference is made to the principle of space kinematics, the trajectory of the edge sweep is as follows
Wherein r is j Representing the point on the jth edge scan in the workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is a vector of (2); r is (r) r A vector representing a point on the cutting edge in a tool coordinate system S2 (o 2, x2, y2, z 2); j represents the distance between the point on the cutting edge on the jth edge scan and the arbor in the tool coordinate system S2 (o 2, x2, y2, z 2); t represents the coordinate system S of the slave tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) To the object coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is set by the following steps:
r r (r)＝[x 2 y 2 z 2 1]'
the simultaneous equations (the parametric equations for the available blade sweeps are:
in the method, in the process of the invention,
the beneficial effects are that: 1. the technical scheme is based on the conjugation principle (the conjugation principle is explained by the noun that when the tooth is cut, the cutter and the workpiece rotate at a certain rotation speed ratio, the finally formed workpiece tooth surface is formed by continuously removing redundant materials in the continuous sweeping process through the cutting edge meeting the line-surface conjugation condition, and the conjugation principle is the above), so compared with other technical schemes adopting the conjugation principle, the technical scheme has the advantages that the conjugation principle is further deduced, the conjugation rotary-cut principle is formed, namely, when the tooth cutting machining is performed, as long as the cutting edge and the theoretical tooth surface of the workpiece meet the conjugation relation, all curves of the conjugation surface of the workpiece and the workpiece tooth surface meet the conjugation relation, and the curves meeting the conjugation relation can be used as the cutting edge of the workpiece tooth surface in the same way. Therefore, the conjugate surface of the theoretical tooth surface of the workpiece is only required to be obtained, and the intersection line of the plane or other regular curved surfaces and the conjugate surface is only required to be obtained, and the intersection line can be used as the cutting edge of the tooth scraping knife.
2. Compared with the technical proposal adopting other deduction principles, the invention belongs to the original invention, and the conjugate rotary cutting principle is utilized to simulate the matrix change during cutting teeth in the technology, so as to generate the shape and the movement track of the cutting edge.
3. Compared with the prior art adopting automatic simulation, the technical scheme utilizes matrix change to include the track (relative position relation) of the cutting edge of the tooth scraping knife on the workpiece for scraping for a plurality of times, thereby being convenient for the subsequent edge scanning and instantaneous tooth slot output to provide theoretical basis and reference track.
Further, the method of generating the instantaneous tooth slot in step S4 is as follows;
i) Specifying a time period t 1 ,t 2 ],t 1 Indicating the start time of the blade sweep, t 2 Indicating the end time of the blade sweep, the time corresponding to the dividing line isThe corresponding time of the sweep-in phase is +.>The corresponding moment of the sweeping-out stage is
ii)S 2 (o 2 ,x 2 ,y 2 ,z 2 ) And a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Assume that a tooth slot Ei of a workpiece is in a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) The resulting tooth surface is F (x, y, z) =0. The final tooth surface of the tooth groove Ei is formed by the last time of the center distance a n The machining allowance is delta n It is assumed that the tooth surface corresponding to the last cutting process is in the workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) G (x, y, z) =0.
The beneficial effects are that: firstly, compared with the blank in the prior art, the technical scheme firstly creatively provides an extraction and generation scheme of the instantaneous tooth slot, the scheme is based on the previous dependent claims (an auxiliary coordinate is constructed to ensure that a static reference surface is unchanged, meanwhile, a motion change matrix is generated by utilizing a conjugate rotary cutting principle, the motion relation and the motion track of a cutter and a workpiece are analyzed, and then the change condition of the track is restrained by parameters such as a rotation angle, an included angle and the like).
Secondly, substituting a time relation in the technical scheme, dividing the tooth cutting knife into a right cutting-in state, a full cutting-in state and a cutting-out state when cutting teeth, simulating the cutting size and thickness of cutting by using the center distances and the machining allowance of different states, feeding back the projection of the workpiece after cutting scraps are eliminated, and generating the instantaneous tooth slot.
Further, the generation of the chip follows the following rule, the time period is substituted, then the track at the corresponding moment of the sweeping-in stage is taken as the main part, and the tooth slot parameter and the cutter parameter are substituted to be combined with the Boolean operation, so that the non-optimized chip shape is obtained.
The technical scheme has the beneficial effects that the time period and the Boolean operation are combined, so that different cuttings in various stages can be generated conveniently, and a model foundation is provided for researching the cutting teeth in different stages.
Further, the following method is referred to for optimization of chips;
the definition of the chip length in the tooth width direction is referred to as follows;
the definition of chip thickness is referred to as follows;
wherein t1 refers to the moment when the j+1th blade surface is in contact with the tooth surface G (x, y, z) =0 just corresponding to the last skiving, t2 refers to the moment when the j-th blade surface is in contact with the tooth surface G (x, y, z) =0 just corresponding to the last skiving, and t3 refers to the moment when the j-th blade surface is in contact with the tooth surface F (x, y, z) =0 just corresponding to the last skiving;
the definition of the chip volume is referred to as follows;
wherein D= { (t, h) |0.ltoreq.t.ltoreq.t 4 ,0＜h≤h(t)}，v 1 S (t, h) is the thickness of the undeformed three-dimensional chip in the width direction in the full cutting stage, and h (t) is the width of the undeformed three-dimensional chip.
The beneficial effects are that: 1. compared with the chip generation method in the prior art (such as Li Zhenjia of Harbin university of worker in visual C++6.0 development platform, and a chip breaking prediction system is constructed by using OpenGL graphic language), the chip breaking prediction method in the technical scheme not only predicts and breaks chips, but also extracts the chips, and is convenient for extracting the chips by limiting the thickness and the width of the chips (the length is determined by the time parameters substituted in the technical scheme).
2. Compared with Dimitriou et al, the method and the device realize extraction of undeformed chips by using the simulation system for cutting teeth, and the technical scheme limits the cutting force of the cutting teeth reversely through the width and the thickness, so that the error of the cutting force in the simulation system is reduced.
Further, according to the spatial geometry, the undeformed three-dimensional chip in the full cutting stage is a spatial geometry obtained by cutting the corresponding tooth surface G (x, y, z) =0, jth edge scan, and jth+1th edge scan, i.e.
Let Q (x, y, z) =0 denote the tooth surface G (x, y, z) =0 corresponding to the last skiving, the jth edge scan, and the jth+1th edge scan intercept to obtain an undeformed three-dimensional chip in the full cutting stage.
The beneficial effects are that: the technical scheme realizes the output of the three-dimensional cuttings, simultaneously carries out parameter definition on the shapes of the cuttings, and improves the simulation degree.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a schematic diagram of a tooth cut machining coordinate system;
FIG. 3 is a graph of the cutting edge simulation effect of MATLAB;
fig. 4 is a swept surface of a cutting edge formed in a workpiece coordinate system S1;
FIG. 5 is a diagram of a three-dimensional blade sweep simulation effect;
FIG. 6 is a schematic view of a family of edge sweeps of a circular arc tooth scraper;
FIG. 7 is a schematic illustration of the stage division of a blade sweep;
FIG. 8 is a schematic view of three cutting stages of a tooth cut process;
FIG. 9 is a schematic illustration of a three-dimensional chip simulation without deformation;
FIG. 10 is a three-dimensional undeformed chip at full cutting stage;
FIG. 11 is a microscope artwork;
FIG. 12 is a microscope label;
FIG. 13 is a chip chart of severe deformation under a microscope
Detailed Description
The following is a further detailed description of the embodiments:
an example is substantially as shown in figure 1: the method for constructing the geometric model of the cutting scraps based on Solidworks comprises the steps of inputting parameters, establishing a cutting edge model, establishing an edge sweeping model, and generating and outputting instantaneous tooth grooves.
Referring to fig. 2, the parameters are input as follows, and a coordinate system is first established: the coordinate system of the workpiece is S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Wherein o 1 Represent S 1 Origin of coordinates of coordinate system, x 1 Axis, y 1 Axis, z 1 The unit vectors of the axes are i respectively 1 ,j 1 ,k 1 ；S p (o p ,x p ,y p ,z p ) Is S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Wherein o is p Represent S p Origin of coordinates of coordinate system, x p Axis, y p Axis, z p The unit vectors of the axes are i respectively p ,j p ,k p 。
The coordinate system of the tool is S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Wherein o 2 Represent S 2 Origin of coordinates of coordinate system, x 2 Axis, y 2 Axis, z 2 The unit vectors of the axes are i respectively 2 ,j 2 ,k 2 ；；S 0 (o, x, y, z) is S 2 (o 2 ,x 2 ,y 2 ,z 2 ) O represents S 0 The coordinate origin of the coordinate system, and the unit vectors of the x axis, the y axis and the z axis are i, j and k respectively.
The tooth surface model of the workpiece is then in a coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Establishing a tool model in a coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Establishing a coordinate system S p And a coordinate system S 0 Is fixed in spatial position.
Finally, the following parameters are established with reference to a coordinate system: (1) the center distance a is the vertical distance between the axis of the tool and the axis of the workpiece; (2) the intersection angle gamma is the included angle between the axis of the tool and the axis of the workpiece; (3) phi (phi) 1 Is the object coordinate system S 1 An angle with which the workpiece rotates relative to the initial position; (4) l is the object coordinate system S 1 Relative to auxiliary coordinates S p Along the axial direction z of the workpiece p Distance of axial forward movement, (5) phi 2 Refers to a tool coordinate system S 2 With the angle of rotation of the tool relative to the initial position.
Referring to fig. 3, the cutting edge model is constructed: the total transformation matrix from the tool coordinate system S2 (o 2, x2, y2, z 2) to the workpiece coordinate system S1 (o 1, x1, y1, z 1) is obtained as
T＝T 20 ·T op ·T p1 (2-1)
Wherein T is 20 From tool coordinate system S 2 To an auxiliary coordinate system S 0 Transform matrix, T op Finger slave auxiliary coordinate system S 0 To an auxiliary coordinate system S p Transform matrix, T p1 Finger slave auxiliary coordinate system S p To the object coordinate system S 1 Is used for the transformation matrix of the (a).
Referring to fig. 4 and 5, the construction of the blade sweep: workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is converted into a tool coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 ) With time parameters t, D 1 Representing t 1 Cutting edge D corresponding to moment i Representation [ t ] 1 ,t 2 ]At a certain time t in i Corresponding cutting edge, D n Representing t 2 Cutting edge corresponding to moment, wherein reference is made to the principle of space kinematics, the trajectory of the edge sweep is as follows
Wherein r is j Representing the point on the jth edge scan in the workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is a vector of (2); r is (r) r Representing the point on the cutting edge in the tool coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Is a vector of (2); j represents the coordinate system S of the tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) The distance between the point on the cutting edge on the jth edge sweep and the arbor; t represents the coordinate system S of the slave tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) To the object coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is set by the following steps:
r r (r)＝[x 2 y 2 z 2 1]'
the simultaneous equations (the parametric equations for the available blade sweeps are:
in the method, in the process of the invention,
and taking the conjugate surface of the theoretical tooth surface of the workpiece as a reference surface, and then adopting a plane or other regular curved surfaces to intersect with the conjugate surface to obtain an intersection line, wherein the intersection line is taken as a cutting edge of the tooth scraper.
Referring to fig. 6 and 7, a time period t is then specified 1 ,t 2 ],t 1 Indicating the start time of the blade sweep, t 2 Indicating the end time of the blade sweep, the time corresponding to the dividing line isThe corresponding time of the sweep-in phase is +.>The corresponding moment of the sweeping-out phase is +.>
ii)S 2 (o 2 ,x 2 ,y 2 ,z 2 ) And a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Assume that a tooth slot Ei of a workpiece is in a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) The final tooth surface is F (x, y, z) =0, and the final tooth surface of the tooth groove Ei is required to be formed with the final center distance of a n The machining allowance is delta n It is assumed that the tooth surface corresponding to the last cutting process is in the workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) G (x, y, z) =0.
And the generation of the chip follows the following rule, the time period is substituted, then the track at the corresponding moment of the sweeping-in stage is taken as the main part, and the non-optimized chip shape is obtained by substituting the tooth slot parameters and the cutter parameters in combination with the Boolean operation.
Output stage: for the optimization of the chip, refer to the following method;
the definition of the chip length in the tooth width direction is referred to as follows;
the definition of chip thickness is referred to as follows;
referring to fig. 8, (wherein (a) is a schematic view of the upper end face just contacted by the blade sweep, (b) is a schematic view of the upper end face just contacted by the blade sweep parting line, (c) is a schematic view of the lower end face just contacted by the blade sweep parting line, (d) is a schematic view of the lower end face to be separated from the blade sweep),
wherein t1 refers to the moment when the j+1th blade surface is in contact with the tooth surface G (x, y, z) =0 just corresponding to the last skiving, t2 refers to the moment when the j-th blade surface is in contact with the tooth surface G (x, y, z) =0 just corresponding to the last skiving, and t3 refers to the moment when the j-th blade surface is in contact with the tooth surface F (x, y, z) =0 just corresponding to the last skiving;
the definition of the chip volume is referred to as follows;
wherein D= { (t, h) |0.ltoreq.t.ltoreq.t 4 ,0＜h≤h(t)}，v 1 S (t, h) is the thickness of the undeformed three-dimensional chip in the width direction in the full cutting stage, and h (t) is the width of the undeformed three-dimensional chip.
According to the space geometry, the undeformed three-dimensional chip in the full cutting stage is a space geometry obtained by cutting the corresponding tooth surface G (x, y, z) =0, jth edge scan, and jth+1th edge scan of the last cutting process, i.e.
Referring to fig. 9, Q (x, y, z) =0 indicates that the tooth surface G (x, y, z) =0, the jth blade scan, and the jth+1th blade scan intersect to obtain an undeformed three-dimensional chip in the complete cutting stage.
The specific implementation process is as follows: the parameters set forth in Table 1 are then chosen according to the procedure described above
Table 1 basic parameters list of tooth cutter and gear workpiece
In the process of cutting teeth, a tooth groove C of the workpiece is used i For example, the p-1 cutter tooth of the tooth-cutting cutter with 22 cutter teeth firstly cuts the tooth groove C of the workpiece i-1 Tooth slot C of the next p-th cutting workpiece i Then the p+1-th cutter tooth cuts the tooth slot C i+1 After a period of time t, the tooth space C is cut again by the No. q cutter tooth of the gear cutting cutter i . Tooth socket C is contacted by the No. p cutter tooth i Tooth slot C of workpiece i To the initial moment, the number q cutter tooth cuts the tooth slot C again after the workpiece rotates once i The time required is t, then
From the geometric relationship, a calculation formula of the chip length along the tooth width direction can be obtained:
wherein n is 1 For the rotation speed of the workpiece, v 1 The workpiece feed speed, f is the feed amount.
The thickness s (t, h) of the chip is the thickness of the three-dimensional undeformed chip at different width positions in the complete cutting stage under the coordinate system of the workpiece, and s (t, h) is defined by s 1 (t, h) and s 2 (t, h) composition, i.e
Where t1 refers to the moment when the j+1th blade surface is in contact with the tooth surface G (x, y, z) =0 corresponding to the last skiving, t2 refers to the moment when the j-th blade surface is in contact with the tooth surface G (x, y, z) =0 corresponding to the last skiving, and t3 refers to the moment when the j-th blade surface is in contact with the tooth surface F (x, y, z) =0 corresponding to the last skiving.
According to the basic theory of differential geometry, the chip volume calculation corresponding to the cutting edge space trajectory can be obtained by the following formulas 2 to 17:
wherein D= { (t, h) |0.ltoreq.t.ltoreq.t 4 ,0＜h≤h(t)}，v 1 S (t, h) is the thickness of the undeformed three-dimensional chip in the width direction in the full cutting stage, and h (t) is the width of the undeformed three-dimensional chip.
According to the space geometry, the undeformed three-dimensional chip in the full cutting stage is a space geometry obtained by cutting the corresponding tooth surface G (x, y, z) =0, jth edge scan, and jth+1th edge scan of the last cutting process, i.e.
Let Q (x, y, z) =0 denote the tooth surface G (x, y, z) =0, the jth edge scan, and the jth+1th edge scan intersection corresponding to the last skiving to obtain an undeformed three-dimensional chip in the complete cutting stage, and a schematic diagram of the undeformed three-dimensional chip simulation obtained by the three-dimensional drawing software solidworks simulation is shown in fig. 2 to 13.
Referring to FIG. 10, tooth slot C is selected herein i-1 As a processing object, the circular arc tooth cutting knife has one cutter tooth for cutting and processing a tooth slot C every time the gear workpiece rotates for one circle i-1 . The coordinate point data of the blade sweeping surface is imported into Solidworks according to the cutter tooth processing sequence, and the arc tooth cutter tooth alignment groove C can be obtained by utilizing the entity cutting function in S i-1 Undeformed three-dimensional chips generated during cutting, chips generated during the complete cutting stage.
Wherein fig. 11, fig. 12 and fig. 13 are pictures taken under a microscope, and the dimensioning of fig. 12 is carried out by the microscope with software measurements. In the tooth machining process, the complete cutting stage accounts for more than 98% of the total tooth machining process, and fig. 13 corresponds to the complete cutting stage in tooth machining.
By observing fig. 11, it can be known that the real chip is wider in the middle and narrower on both sides, and by combining the dimension marking of fig. 12, it can be known that the real chip has the greatest thickness in the middle and gradually decreases towards both sides, and it can be approximately considered that the real chip is obtained by intersecting two circular arcs, and the contour of the real chip is similar to a crescent.
Comparing the picture with the picture in fig. 10, the similarity between the undeformed chip and the real chip of the three-dimensional modeling of the solidworks simulation software can be known to be higher, and the simulation effect of the undeformed chip of the three-dimensional modeling of the solidworks simulation software is better. By observing fig. 13, it can be known that the undeformed chip is greatly deformed in the tooth cutting process, and the undeformed chip has more remarkable curl and tear.
The tooth cutting machining process comprises a cutting-in stage, a complete cutting stage and a cutting-out stage, wherein the specific gravity of the cutting-in stage and the cutting-out stage is very low, and in addition, undeformed chips formed by the two stages are relatively long and narrow, and curling and tearing are very easy to occur in the tooth cutting machining process, so that real chips corresponding to the cutting-in stage and the cutting-out stage are difficult to find in a large quantity of real chips.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The foregoing is merely an embodiment of the present invention, and a specific structure and characteristics of common knowledge in the art, which are well known in the scheme, are not described herein, so that a person of ordinary skill in the art knows all the prior art in the application day or before the priority date of the present invention, and can know all the prior art in the field, and have the capability of applying the conventional experimental means before the date, so that a person of ordinary skill in the art can complete and implement the present embodiment in combination with his own capability in the light of the present application, and some typical known structures or known methods should not be an obstacle for a person of ordinary skill in the art to implement the present application. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the structure of the present invention, and these should also be considered as the scope of the present invention, which does not affect the effect of the implementation of the present invention and the utility of the patent. The protection scope of the present application shall be subject to the content of the claims, and the description of the specific embodiments and the like in the specification can be used for explaining the content of the claims.
Claims (1)
1. The method for constructing the geometric model of the cutting scraps based on Solidworks is characterized by comprising the following steps of: creating a workpiece geometric entity by using a simulation system, constructing a cutting edge model of a tooth cutter, constructing an edge scanning model formed by cutting edges on cutter teeth of the tooth cutter on a workpiece coordinate system relative to the workpiece according to the motion relationship and the position relationship between the tooth cutter and the workpiece, combining a workpiece blank with an edge scanning surface, performing Boolean operation between the edge scanning surface and an instantaneous tooth slot geometric entity to form undeformed chips and new instantaneous tooth slots, and outputting an undeformed three-dimensional chip geometric model of a certain cutter tooth of the tooth cutter in the cutting process after the simulation is finished;
comprises the following steps of;
s1, inputting parameters, respectively establishing a workpiece coordinate system, a workpiece auxiliary coordinate system, a tool coordinate system and a tool auxiliary coordinate system, establishing a workpiece tooth surface model on the basis of the workpiece coordinate system, and simultaneously bringing vector coordinates to limit a center distance, an intersection angle and an initial rotation angle;
s2, a cutting edge model is established, a conjugate surface of a theoretical tooth surface of a workpiece is used as a reference surface, then a plane or other regular curved surfaces are adopted to meet the conjugate surface to obtain an intersection line, and the intersection line is used as a cutting edge of the tooth scraper;
s3, converting a cutting edge and a workpiece coordinate system by the edge scanning model, and taking time parameters to divide the edge scanning model into a partial cutting-in state, a complete cutting-in state and a cutting-out state so as to form a continuous curved surface;
s4, generating an instantaneous tooth slot, and carrying out Boolean operation on the blade sweeping surface and the geometrical entity of the instantaneous tooth slot;
s5, outputting, and generating three-dimensional undeformed chips and instantaneous tooth grooves;
in the step S1, the method for establishing the coordinate system is as follows, and the coordinate system of the workpiece is S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Wherein o 1 Represent S 1 Origin of coordinates of coordinate system, x 1 Axis, y 1 Axis, z 1 The unit vectors of the axes are i respectively 1 ,j 1 ,k 1 ；S p (o p ,x p ,y p ,z p ) Is S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Wherein o is p Represent S p Origin of coordinates of coordinate system, x p Axis, y p Axis, z p The unit vectors of the axes are i respectively p ,j p ,k p ；
The coordinate system of the tool is S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Wherein o 2 Represent S 2 Origin of coordinates of coordinate system, x 2 Axis, y 2 Axis, z 2 The unit vectors of the axes are i respectively 2 ,j 2 ,k 2 ；S 0 (o, x, y, z) is S 2 (o 2 ,x 2 ,y 2 ,z 2 ) O represents S 0 The coordinate origin of the coordinate system, and the unit vectors of the x axis, the y axis and the z axis are i, j and k respectively;
the tooth surface model of the workpiece is then in a coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Establishing a tool model in a coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Establishing a coordinate system S p And a coordinate system S 0 Is fixed in space position;
finally, the following parameters are established with reference to a coordinate system: (1) the center distance a is the vertical distance between the axis of the tool and the axis of the workpiece; (2) the intersection angle gamma is the included angle between the axis of the tool and the axis of the workpiece; (3) phi (phi) 1 Is the object coordinate system S 1 An angle with which the workpiece rotates relative to the initial position; (4) l is the object coordinate system S 1 Relative to auxiliary coordinates S p Along the axial direction z of the workpiece p Distance of axial forward movement, (5) phi 2 Refers to a tool coordinate system S 2 An angle with which the tool rotates relative to the initial position;
the matrix change conditions for the cutting teeth are as follows:
wherein T is 20 From tool coordinate system S 2 To an auxiliary coordinate system S 0 Transform matrix, T op Finger slave auxiliary coordinate system S 0 To an auxiliary coordinate system S p Transform matrix, T p1 Finger slave auxiliary coordinate system S p To the object coordinate system S 1 Is a transformation matrix of (a);
in step S3, constructing a cutting edge sweeping surface according to a track of the conjugate principle, wherein the construction method comprises a) or b);
a) Coordinate system S of tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) Is converted into a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Or (b)
b) Coordinate system S of the workpiece 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is converted into a tool coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 )；
Carrying in time parameter t, D in b) 1 Representing t 1 Cutting edge D corresponding to moment i Representation [ t ] 1 ,t 2 ]At a certain time t in i Corresponding cutting edge, D n Representing t 2 The cutting edge corresponding to the moment, wherein the principle of space kinematics is referenced, the track of the edge sweeping surface is as follows:
wherein r is j Representing the point on the jth edge scan in the workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is a vector of (2); r is (r) r Representing the point on the cutting edge in the tool coordinate system S 2 (o 2 ,x 2 ,y 2 ,z 2 ) Is a vector of (2); j represents the coordinate system S of the tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) The distance between the point on the cutting edge on the jth edge sweep and the arbor; t represents the coordinate system S of the slave tool 2 (o 2 ,x 2 ,y 2 ,z 2 ) To the object coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Is set by the following steps:
r r (r)＝[x 2 y 2 z 2 1]'
the parametric equation for the simultaneous formula available edge sweep is:
in the method, in the process of the invention,
the method of generating the instantaneous tooth slot in step S4 is as follows;
i) Specifying a time period t 1 ,t 2 ],t 1 Indicating the start time of the blade sweep, t 2 Indicating the end time of the blade sweep, the time corresponding to the dividing line isThe corresponding time of the sweep-in phase is +.>The corresponding moment of the sweeping-out phase is +.>
ii)S 2 (o 2 ,x 2 ,y 2 ,z 2 ) And a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) Assume that a tooth slot Ei of a workpiece is in a workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) The final tooth surface is F (x, y, z) =0, and the final tooth surface of the tooth groove Ei is required to be formed with the final center distance of a n The machining allowance is delta n It is assumed that the tooth surface corresponding to the last cutting process is in the workpiece coordinate system S 1 (o 1 ,x 1 ,y 1 ,z 1 ) G (x, y, z) =0;
substituting a time period for chip generation, and substituting tooth slot parameters and cutter parameters into Boolean operation to obtain an unoptimized chip shape by taking a track at a corresponding moment in a sweeping-in stage as a main part;
for the optimization of the chip, refer to the following method;
for the tooth width along directionThe definition of the chip length is referred to as follows;
the definition of chip thickness is referred to as follows;
wherein t1 refers to the moment when the j+1th blade surface is in contact with the tooth surface G (x, y, z) =0 just corresponding to the last skiving, t2 refers to the moment when the j-th blade surface is in contact with the tooth surface G (x, y, z) =0 just corresponding to the last skiving, and t3 refers to the moment when the j-th blade surface is in contact with the tooth surface F (x, y, z) =0 just corresponding to the last skiving;
the definition of the chip volume is referred to as follows;
wherein D= { (t, h) |0.ltoreq.t.ltoreq.t 4 ,0＜h≤h(t)}，v 1 S (t, h) is the thickness of the undeformed three-dimensional chip in the width direction in the full cutting stage, and h (t) is the width of the undeformed three-dimensional chip;
according to the space geometry, the undeformed three-dimensional chip in the full cutting stage is a space geometry obtained by cutting the corresponding tooth surface G (x, y, z) =0, jth edge scan, and jth+1th edge scan of the last cutting process, i.e.
Let Q (x, y, z) =0 denote the tooth surface G (x, y, z) =0 corresponding to the last skiving, the jth edge scan, and the jth+1th edge scan intercept to obtain an undeformed three-dimensional chip in the full cutting stage.
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