| Summary: | 碩士 === 國立臺灣科技大學 === 機械工程系 === 100 === Face-hobbing method is a continuous cutting process. It has high productivity, precision, and produced gears with better contact bearing. Nevertheless, this method is implemented in the hypoid gear and spiral bevel gear cutting process, and generates extended epicycloidal flanks. In 2009, the German company Klingelnberg disclosed a new face-hobbing method for manufacturing the straight bevel gears. Klingelnberg introduced a hypocycloidal straight mechanism for cutting straight bevel gears. In this mechanism, setting the radius of the rolling circle equals to half of the radius of the base circle yields straight lines.
The mathematical model of the face-hobbed straight bevel gear developed based on a universal cradle-type face-hobbing bevel gear generator is given. We want to make an experiment to verify the correction of the established mathematical model of face-hobbed straight gear. However, this universal cradle-type generator is a virtual machine, which cannot be used in the real manufacture. Instead, we use the six-axis CNC bevel gear cutting machine as the experiment machine. In this thesis, the machine settings of the six-axis CNC bevel gear cutting machine are derived from the universal cradle-type generator. According to the Gleason Works technical report about the face-hobbing cutting system for spiral bevel and hypoid gears, we program the NC codes for manufacturing face-hobbed straight bevel gears. Furthermore, a flank topographic correction method is developed based on the six-axis CNC bevel gear cutting machine. Finally, in order to verify the six-axis machine settings and the NC codes, the cutting experiment is implemented. The flank deviations of finished gears are obtained by the gear measuring center. And according to the proposed correction method, The corrections on the cutter parameters and machine settings are calculated. The results of experiments verify the correction of proposed mathematical models.
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