球面狀工件在工業中廣泛應用，尤其雙包絡蝸桿在具有空間限制及高減速比需求之設備中得到更廣泛應用。相較於非包絡蝸桿，雙包絡蝸桿具有更高的傳動效率及接觸比，因此提出高效加工雙包絡蝸桿之方法變得至關重要。本研究提出了應用旋風式銑削於加工ZK型雙包絡蝸桿之泛用方法。旋風式銑削方法具有高精度且高效之加工特點，優於傳統的銑削加工方法。同時，滾齒凸輪相對於其他凸輪從動件系統更具有優勢。然而，目前尚未將旋風式銑削應用於滾齒凸輪之加工製造中。因此，本研究同時提出了應用旋風式銑削於加工滾齒凸輪之創新方法，並且建立了用於球面狀轉子表面加工之泛用數學模型，該方法通過使用盤型刀具同時加工工件兩側。透過虛擬切削模擬與分析，驗證了球面狀轉子表面之加工之可行性。提出了機械設定和座標系統，同時亦建立了刀具與工件表面之數學模型。驗證了應用於機台生成工件表面之加工可行性。通過使用旋風式銑削和盤型切削刀具進行球面狀轉子表面加工之數值模擬，求解了切削點的數值解以及球面狀轉子表面之法向誤差。在不考慮磨削和考慮磨削余量之情況下，對數學建模進行驗證，並針對機械設定對於法向誤差之敏感度進行分析，探討各加工軸附加運動對加工效果之影響。在考慮切削工具裝配誤差情況下，使用Levenberg–Marquardt算法對機械設定進行了數值求解。使用VERICUT進行了虛擬切削模擬，並對數學模型進行了驗證。最後，提供了加工實例之結果，以驗證本研究所提出之方法在製造球面狀轉子表面方面的優勢。;Workpieces with a globoidal shape have been used extensively in industry. Double-enveloping worms (DEWs) are widely used in many applications, especially space-saving and high-reduction ratio equipment. DEWs have a higher transmission efficiency and contact ratio than non-enveloping worms. Proposing an effective and efficient method for machining the DEW is an issue that needs to be solved. This study offers a general method to manufacture ZK-type worms of DEW using a whirl-machining process. The whirl-machining process is a precise, efficient, and promising machine process for manufacturing workpieces over the milling process. At the same time, the roller-gear cam has advantages over the other cam-follower system. However, the whirl-machining process has yet to be applied to manufacture the roller-gear cam. Therefore, this study also proposes a novel method for roller-gear cam manufacturing using a whirl-machining process. Furthermore, a novel general mathematical model for globoidal rotor surface machining is developed. The machining process for both flank surfaces of the workpiece is conducted simultaneously using a disk-type cutting tool. Analytical and virtual cutting simulation on globoidal rotor surface machining is investigated. The machine setting and the coordinate system are proposed. A mathematical model for the surface of the tool and workpiece is presented. The generation of the workpiece surface on the offered machine is investigated. The machining process simulation of the globoidal rotor surface by the whirl-machining and disk-type cutting tool, the numerical solution of cutting points, and the normal deviation of the globoidal rotor surface are solved. Verification of mathematical modeling without considering grinding and considering grinding allowance, sensitivity analysis for machine-axis settings concerning normal deviation, the influence of additional movements for each machining axis, a simulation machining with cutting tool assembly error, and the the numerical solution for machine-axis settings using Levenberg–Marquardt algorithm are conducted. Virtual cutting simulation is presented using VERICUT. Verification of mathematical modeling is conducted. Results from the machining examples are presented to verify the advantages of manufacturing the globoidal rotor surfaces in the proposed method.
