本論文旨在結合螺旋鉋齒刀之齒形研磨與鉋齒加工，針對砂輪輪廓對工件齒輪齒形誤差之影響進行最佳化與分析。利用齒輪原理和螺旋鉋齒刀齒形研磨的機械設定，建立砂輪創成螺旋鉋齒刀之齒面數學模式，其中螺旋鉋齒刀包含了頂隙角、側隙角、前角以及刃口面。根據螺旋鉋齒刀和鉋齒加工的機械設定，建立螺旋鉋齒刀創成工件齒輪之齒面數學模式，再計算鉋齒加工所得到之工件齒輪之齒形誤差，並對不同鉋齒刀重磨參數下的工件齒輪齒形誤差進行趨勢分析。 最佳化部分，首先提出砂輪輪廓之初始設計方法，將工件齒輪在節圓處的誤差進行消除，接著以多項式曲線取代原本的直邊砂輪，建立一套砂輪輪廓最佳化之方法，並提出一組螺旋鉋齒刀與工件齒輪的參數設定，探討砂輪輪廓最佳化方法之正確性。為了增加螺旋鉋齒刀之有效重磨量，在鉋齒加工加入螺旋鉋齒刀之補償角並進行最佳化，根據模擬結果顯示，砂輪輪廓設計與最佳化可成功降低工件齒輪之齒形誤差。 ;This thesis aims to optimize the analysis of the influence of the grinding wheel on the tooth profile errors of the workpiece by combining the tooth profile grinding and the gear cutting of the helical gear cutter. The mathematical model of helical shaper cutter with the head clearance angle, the backlash angle, the front angle and the cutting edge surface generating by grinding wheel was established based on the theory of gearing and the mechanical setting of the helical shaper cutter grinding. According to the helical shaper cutter and the mechanical setting of gear shaping, the mathematical model of the workpiece gear was developed. Then the tooth profile errors of the workpiece gear obtained by the gear shaping were calculated, and the trend of tooth profile errors of the workpiece under different resharpening length were analyzed. In the optimization aspect, the initial design method of the grinding wheel profile is first proposed to eliminate the error of the workpiece gear at the pitch circle. Then the original straight-side grinding wheel is replaced by a polynomial curve to establish a method for optimizing the contour of the grinding wheel, and propose the parameters of a set of a helical shaper cutter and a workpiece gear to explore the correctness of the method of optimizing the contour of the grinding wheel. In order to increase the effective re-grinding amount of the helical shaper cutter, the compensation angle of the helical shaper cutter was added to the gear shaping process and optimized. According to the simulation results, the contour design and optimization of the grinding wheel can successfully reduce the tooth profile errors of the workpiece gear.
