Feature-Based Shaving Cutter Modeling And Deformation Analysis

Gear shaving is a gear-finishing process. With the characteristic of high efficiency and high precision it is widely used as a gear finish process by most gear-making factories. Yet pne of the shortcomings of shaving process is that if profile of the tooth of shaving cutter is of standard involute, the profile of the shaved gear by this shaving cutter will be concaved by about 0.01~0.03 mm around the middle part of the its profile, which is professionally called mid-concave error. Gears shaved like this will induce great driving error, generate much more noise while running, and shorten greatly the operating life of the gears. Although much has been achieved on the research of mechanics of shaving process, there is not much quantitative description about the weight of each error-generating factor to the generation of mid-concave error due to the complexity of shaving process.Based on classical principles and most recent researches of this field, the author brings forward some reasonable suggests and, with the aid of advanced software, draw some valuable conclusions that will be helpful to the improvement of shaving process.Against the background of the most recent researches, the author has done some work as follows. Study and summarize the basic theories and principal achievements of shaving process research; represent main factors that induce mid-concave error. Develop the software used to create feature-based & parameterized 3D models in MDT, which accelerates the model-creating speed of shaving cutters, spur and helical gears; models created this way can be exported in different data formats that can be utilized by other CAD/CAE software. Based on actual manufacture system and the aim of this project, an abstract 3D model with concentrated forces imposed on it is constructed to simulate actual shaving process, which simplifies the analytical process and exposes the object to study to researchers; multifunctional FEM software is used to carry out the analysis and many valuable results such as Load Distribution Graph among Mesh Teeth and Composite Deformation Graph of Mesh Position are got.