| Summary: | 博士 === 國立中正大學 === 機械系 === 99 === Form grinding method has been widely used to manufacture high precision thread on cylindrical workpieces. This thesis proposes a design of form milling cutter with multiple inserts for roughing process and computerized numerical simulation methods instead of simultaneous system equations for finishing process. The research subjects are:
1. Based on the geometrical relations, a geometric approach to determine the grinding wheel profile with or without a tilt angle is presented. Instead of simultaneous system equations, the grinding wheel profile calculated by the proposed method cuts off no extra material even when undercutting occurs.
2. A simplified 2D simulation method executed in AutoCAD ObjectARX CAD software by executing a script file generated by Visual C++ for simulating gear manufacturing process is proposed. The simulation method is demonstrated by taking the cases of manufacturing processes of the cylindrical gear and hypoid gear below with form grinding and face milling processes, respectively.
3. Based on the geometrical relations, this thesis proposes a simplified two-dimensional numerical simulation method for form grinding the thread on cylindrical workpieces without solving the simultaneous system equations that produce numerically unstable solutions in the presence of undercutting, interference, or double enveloping.
4. Based on the equal wear rate for insert cutting edges and the geometrical tolerance, a mathematical model for finding the distribution of cutter body inserts is proposed. The tool life of the insert in every position is estimated based on its cutting material volume and corresponding wear rates for making geometric precision easier to maintain when the insert’s cutting edges become dull.
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