Research And Simulation On Optimization Of Process Parameters For High-Speed Dry Gear Hobbing

Gear is an important part in mechanical transmission system,and plays an important role in aerospace,automobile manufacturing,machine tool manufacturing and other fields.As the basis of gear application,gear manufacturing is also developing towards high-end technology manufacturing with the improvement of industrial demand.Gear hobbing occupies a large proportion in gear manufacturing,and has the advantages of high production efficiency and good processing quality.Traditional gear hobbing is inseparable from the use of cutting fluid.Extensive use of cutting fluid will not only increase the processing cost,but also pollute the workshop environment and endanger the health of workers.At the same time,with the proposal of "Made in China 2025",traditional gear hobbing goes against modern times.Green manufacturing requirements.In recent years,high-speed dry gear hobbing technology has emerged as the times require.It adopts higher cutting speed and abandons the use of cutting fluid.However,because of this,the friction between the tool and the workpiece increases during processing,resulting in excessive cutting force and excessive cutting force.The temperature rise in the cutting area is too high.Adjusting the dry hobbing process parameters will significantly change the force on the tool and the shape of the chip,and the chip will take away most of the heat generated during processing.Therefore,the optimization research of dry hobbing process parameters is of great significance for the development of high-speed dry hobbing.Due to the great difference between high-speed dry gear hobbing and traditional gear hobbing,there are still many problems in the related research.In view of the above problems,this paper mainly carries out the following work:(1)Select machining time and machining cost as objective functions,and establish a mathematical model of high-speed dry gear hobbing process parameters with machining cost and machining time as objective functions according to the existing research results.(2)Sensitivity analysis of all relevant process parameters of dry hobbing was carried out by using Sobol' method,and sorting was carried out,and two items were determined as optimization variables from a number of process parameters,namely feed speed and hob rotation speed.(3)For the two selected process parameters,the particle swarm optimization algorithm is used to carry out multi-objective optimization solutions under the constraints of the minimum processing time and the minimum processing cost,and the optimal parameter solutions are obtained.(4)Finite element analysis is carried out on the optimal process parameter solution set.Since the force-heat coupling relationship is obvious in gear hobbing,this paper conducts finite element simulation analysis from two aspects of cutting force and cutting heat.Change the hob speed and feed speed to complete six cutting force simulations.It is analyzed that under the optimal parameter solution,the cutting force will not fluctuate greatly,and the production efficiency of the workpiece can be increased;the temperature of the cutting zone is simulated.,under the optimal process parameters,the thermal deformation problem that affects the tool life and gear machining quality will not occur in the cutting area.