【摘要】 针对盘形齿轮铣刀铣削力计算模型未考虑螺旋齿面几何特征、难以适用于斜齿加工的问题，构建了融合螺旋特性的斜齿铣削力动态预测模型。首先，依据斜齿轮齿面螺旋方程与刀具回转面约束条件，精确求解斜齿轮盘形齿轮铣刀刀齿廓形；进而，基于刀具和工件动态啮合关系，分别建立了斜齿轮不同加工阶段的切削宽度计算模型，并考虑刀具跳动因素，建立了精确的切削厚度计算模型；最后，通过动态切削宽度与切削厚度的联合计算获取瞬时切削面积，结合材料特性与切削力系数，构建了成形铣齿铣削力动态预测模型，并通过实际切削实验对模型进行了实验验证。结果表明：该模型预测的铣削力在进给方向上的最大误差为12.57%,在切深方向上的最大误差为21.01%,且波形与实验数据具有良好一致性。针对不同螺旋角斜齿轮的铣削力分析表明，在进给方向与切深方向上，铣削力均随螺旋角的增大呈现减小趋势。更多还原

【Abstract】 A dynamic prediction model for helical gear milling forces, incorporating helical characteristics, was developed. This work aimed to address the problem that existing force calculation models for disc-type gear milling cutters neglect the geometric features of helical tooth surfaces and are thus unsuitable for helical gear machining. Firstly, based on the helix equation of the helical gear tooth surface and the constraint conditions of the tool revolution surface, the tooth profile of the disc-type gear milling cutter for helical gears was precisely solved. Then, using the dynamic meshing relationship between the tool and the workpiece, cutting width calculation models for different machining stages of the helical gear were established respectively. Considering tool runout, an accurate cutting thickness calculation model was also established. Finally, the instantaneous cutting area was obtained through the combined calculation of dynamic cutting width and cutting thickness. By incorporating material properties and cutting force coefficients, a dynamic prediction model for form milling forces was finally constructed. The model was experimentally verified through actual cutting tests.Results showed that the maximum prediction error of the proposed model was 12. 57% in the feed direction and 21. 01% in the depth direction. A good consistency between the predicted waveforms and the experimental data was observed. Furthermore, milling force analysis for helical gears with different helix angles indicated that the milling forces in both the feed direction and the depth direction exhibited a decreasing trend as the helix angle increased.更多还原