Abstract: Aiming at the problems that big normal deviation and maldistribution of tooth surface existed in the process of single cutter helical gear milling,a new method of duplex cutter helical gear milling was proposed.Based on the spatial envelope principle,the mathematical model of duplex cutter gear milling was obtained.In addition,the transverse-profile of tooth surface and normal deviation enveloped by duplex cutter were calculated by parsing algorithm.Under the premise of no overcutting,the cutter spacing adjustment range was calculated.Combined with the shaft center distance of duplex cutter,the relationships between the maximum normal deviation of transverse-profile surface and the shaft center distance of duplex cutter as well as the cutter spacing were also analyzed.According to the relationship,base on the constraint conditions of the key parameters of duplex cutter gear milling,the shaft center distance of duplex cutter and the cutter spacing were adjusted.To reduce the tooth surface maximum normal deviation,the optimization of these key parameters was researched by using discrete variable grid direct optimization algorithm.Thus,the optimization of transverse-profile's normal deviation was realized.The physical prototype test showed that the optimization method could effectively reduce the tooth surface maximum normal deviation.

Key words: duplex cutter gear milling, spatial envelope principle, maximum normal deviation of transverse-profile, parameter optimization

摘要： 针对直线廓形的单铣刀盘铣削斜齿轮时齿面法向偏差较大且分布不均匀的问题,提出一种双铣刀盘铣齿法来减少齿面法向偏差。根据空间包络原理,对双刀盘铣齿进行建模并通过解析算法求取双刀盘所包络的端面齿形和齿面法向偏差。在不过切的前提下,求取刀盘间距的调整范围,并结合刀轴中心距分析两者与齿面最大法向偏差的关系。根据所得规律,以双刀盘铣齿关键参数—刀盘间距、刀轴中心距与法向偏差的关系为约束条件,通过调整刀盘间距与刀轴中心距,使用离散变量网格直接寻优算法,以减少齿面最大法向偏差为优化目标,对双刀盘铣齿关键参数进行优化研究,从而实现对齿面法向偏差的优化。通过物理样机试验表明,该优化方法可有效减少齿面最大法向偏差。

关键词: 双刀盘铣齿, 空间包络理论, 齿面最大法向偏差, 参数优化