Cutting Simulation for Face-Milled Spiral Bevel Gears Based on the Voxel Method

• Main Authors: Hao-Hsiang Chuang, 莊皓翔
• Other Authors: Shih yi-pei
• Format: Others
• Language: zh-TW
• Published: 2014
• Online Access: http://ndltd.ncl.edu.tw/handle/18803659895076081969

碩士 === 國立臺灣科技大學 === 機械工程系 === 102 === Face milling is a popular cutting method in mass production of spiral bevel gears. A CNC machine with five-axis simultaneous control system is demanded to implement face milling. This cutting method needs multi-axis movement and its tool design is complex. Therefore, in order to avoid collision, the simulation of tool paths and material removal should be performed previously to verify the correctness of NC codes. The study aims to develop a dedicated cutting simulation software for face-milled spiral bevel gears. Visual C# 2010 integrated with OpenGL is used as a foundation to develop the simulation program. Here, a voxel method for cutting simulation is employed. The mathematical model of tool surface is first established. The solid model of work gear is composed by cubes in which voxels are used to store the positions and values of those vertexes. According to the NC code, the relative positions between the tool and the work gear are determined through the coordinate transformations. And then, Boolean difference operation between the gear work and tool is made to simulate gear cutting. Moreover, the marching cube algorithm is adopted to improve the display resolution of produced tooth surfaces which are save as STL (Stereolithography) format. In order to verify the correctness of NC codes, an evaluation method is proposed to obtain tooth surface deviations between the produced STL surfaces and theoretical surfaces. And, the volume removal is obtained in real-time cutting simulation, which can be used as a beneficial data for further reach in optimization of NC tool paths.