A Research On Design Method Of Theoretical Error-Free Cutting Edge Profile Shaper Cutter

Shaper Cutter is one of the most widely used gear cutting tools.However,the current shaper cutters exist some problems,such as the theoretical tooth profile error,poor accuracy of consistency after resharpening,and it is difficult to increase the rake and rear angles under the conditions of ensuring tooth profile accuracy.Aiming at these problems,this paper presents a general design method of theoretical error-free cutting edge profile shaper cutter based on the understanding of the research results of gear shaper at home and abroad.Firstly,starting from the structure of shaper cutter,the cause of the problem was analyzed,and a new design principle of shaper cutter was proposed.According to the gear engagement principle,a mathematical model of the virtual gear tooth surface was first built.Then using sphere surface as rake face,a general mathematical model of the rake face was established to meet the design requirements of straight-teeth and helicalteeth shaper cutter simultaneously.Then the theoretical error-free cutting edge was obtained by surface intersection of the virtual gear tooth surface and the rake face.To ensure the accuracy of consistency after resharpening,the flank face was constructed by a series of theoretical error-free cutting edges.The design procedure of the new shaper cutter was given,and the feasibility of the method was verified by an example.Secondly,through testing the design results,the drawbacks of the existing method were analyzed.The result of the design was verified by VERICUT simulation.Based on the principle of simulation experiment,a simulation model of gear shaping machine was built according to the movement process of gear shaping.The NC program was compiled based on actual gear shaping.In order to validate the correctness and superiority of the design results,a comparative experiment was conducted with the existing method.Finally,the conclusion was obtained by comparing the simulation results of two kinds of shaper cutter.Finally,based on the previous research results,a design system of shaper cutters was developed by using VB and Matlab,and the feasibility of the design system was verified by design examples.