本研究為二年期研究計畫，因動力刮削刀具結構近似於螺旋鉋齒刀，考慮到實務上的可行性和成本考量，本研究計畫將以模擬方式建立一套與實務結合之動力刮削刀具與切齒設計流程。在第一年首先由磨輪創成運動推導出動力刮削刀具齒面數學模式；其次，建立動力刮削運動座標關係，以前述推導之刀具數學模型創成工件齒面數學模型，配合拓樸誤差程式計算出齒面拓樸誤差，並根據敏感性分析選擇影響誤差值之設計變數，建立動力刮削刀具設計之最佳化計算方法，分別得到齒面精度達到DIN 7級以上內正齒輪與內螺旋齒輪之刀具刃口線與對應之磨輪輪廓曲線。接著，考量刀具重磨後對工件齒面拓樸誤差的影響，加入工件補償角設定，建立補償角最佳化演算法以得到維持相同精度等級下之最大刀具有效重磨量，完整建立可重磨之動力切削刀具及最佳化設計流程，預期將可建立一套從磨輪到工件的完整設計方法與流程，並提供實際加工時機台於不同重磨量下的工件補償角設定。第二年將針對先前申請人團隊近年研究之諧波齒輪研究中，所推導之與漸開線柔輪共軛之剛輪以及切線雙圓弧柔輪共軛之剛輪，進行以動力刮削進行剛輪加工與刀具設計之研究。將由剛輪齒形逆向推導使用動力刮削加工之刀具刃口面曲線，並進一步推導使用磨輪創成該動力刮削刀具之磨輪外型輪廓。接著，並加入刀具刃口面之重磨考量，完整建立切削諧波齒輪之剛輪的可重磨之動力刮削刀具設計，並且針對不同重磨量下的齒形誤差提出六軸機台同動之誤差補償方式，使得此設計符合實務，並可實際應用於剛輪加工。本研究之完成，將可有效提升國內齒輪製造技術，尤其在動力刮削刀具設計能力及諧波齒輪之剛輪設計及製造技術。 ;This research project is a two-year project. A power-skiving cutter resembles a helical shaper cutter. In the first year, the manufacturing process of internal gears by power skiving is investigated, considering the practical design considerations of cutter design and regrindable cutter. First, a generating wheel is used to generate the power-skiving cutter. Then the cutter is applied to generate internal spur gear and internal helical gear by power skiving method. The surface topology of the generated internal gear tooth profiles will be calculated and an optimization algorithm will be integrated with the tooth profile program to minimize the surface topology error to an acceptable precision grade, i.e. DIN 7. Therefore the optimum profile of the generating grinding wheel will be achieved, and the corresponding cutting edge profile of the power-skiving cutter will also be obtained. Besides, the regrindable cutter rake-face will also be an studied and the effect of the reground rake face on the precision of the internal gear tooth profile will also be investigated. An optimization algorithm will be utilized to determine the optimum compensation angle of the workpiece during power skiving process to minimize the effect on the tooth profile precision resulting from cutter regrading. Therefore, a complete design process of producing internal gear by power skiving will be accomplished and presented.In the second year, on the basis of our recent research on the harmonic drive, the production of circular spline of the harmonic drive will be studied by using power skiving. Two types of circular splines, involute and double-circular-arc, will be studied and their respective cutter design will be designed. Moreover, the regrindable power-skiving cutter for the circular splines will also be investigated and proposed. Finally, the circular splines of harmonic drives can be manufactured on a 6-axis CNC power skiving machine with specific cutter designs.This research project is believed to be beneficial for the domestic gear manufacturing industry as well as harmonic drive production in Taiwan.
