圆柱齿轮滚齿切削力的预测

切削力是滚齿工艺参数优化、刀具磨损预测和机床设计的重要依据. 针对圆柱齿轮滚齿加工，提出了一种基于实体建模技术的切削过程几何仿真方法，实现了未变形切屑的准确提取，进而计算出未变形切屑厚度. 基于微分离散思想，将滚刀刀齿切削刃离散成一系列微元切削刃，采用Kienzle-Victor力模型，建立微元切削力模型，进而构建整体滚刀切削力模型. 结合Kistler 9123C旋转测力仪和DMU50五轴立式加工中心进行滚齿切削力测量试验，试验结果表明，预测的滚削力在幅值和变化趋势上与试验测量结果吻合良好，验证了该滚削力预测方法的有效性.

Prediction of Cutting Forces in Gear Hobbing of Cylindrical Gears

The cutting forces involved during gear hobbing play an important role in process parameter optimization， hob wear prediction and hobbing machine design. The geometrical simulation of the gear hobbing process based on solid modelling was realized. Solid chips were extracted accurately and undeformed chip thickness was calculated. To model the hobbing process， the tool cutting edge was divided into small differential cutting edge segments. The cutting forces exerted on each cutting edge element were calculated based on Kienzle-Victor′s equations and the total force components acting on the hob were obtained by integrating the elementary force components. To validate the predictive model of gear cutting forces， the experiments were carried out in DMU50 five-axis CNC machining center equipped with a Kistler 9123C rotary dynamometer. The simulation results are compared with the experiments. The cutting process is well captured by the predictive model， and good correlations in cutting forces are observed between the predictions and experiments.