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 雙螺旋式真空泵之核心元件為一對由同步齒輪帶動且反向旋轉的螺旋轉子，而此螺旋轉子為維持氣密性常使用一種可形成內凹齒腹的擺線來進行設計並以成形研磨法加工，然而此類轉子因過切而無法以單一成形刀具完成加工，大大地降低效率，本文提出一新型的刀傾成形磨齒法（TFG），可解決原成形法中過切的問題，並以單一刀具完成定導程轉子的加工，更進一步地，左、右旋轉子在刀傾角只具單一旋轉方向時，皆可以用同一把成形刀具來加工，而數值範例的結果亦驗證了所提出的TFG之可行性。定導程螺旋轉子雖然能以成形法來進行加工，但變導程轉子則不能以成形法生產，因此本文提出以數值控制車床(CNC Lathe)來進行變導程轉子加工的方法，在此法中我們利用轉子的軸向線形來對車刀片的初始位置與行進軌跡來進行計算與排列，且也推導了誤差模型來進行驗證，參照數值範例的結果，進一步地驗證了本文中所提出的方法是可行的，但仍需進行實驗來確認刀具壽命與加工精度。真空泵螺旋轉子運作時，彼此之間維持一定間隙且不接觸，其運動完全仰賴一對同步齒輪來維持，而一旦齒輪產生損壞或變形則將會造成轉子卡死（Lock-up）或干涉，因此如何決定適合工作的齒輪對，強度計算是首要考量，本文整合了混合有限元法（HFEM）與齒面接觸分析（TCA）對嚙合圓柱齒輪組的靜態接觸進行計算，而本文中的結果也與ANSYS進行了比對，本文所提出的HFEM亦可用在齒面修型量的研究上。關鍵字:螺旋轉子,變導程,刀傾成形磨齒法,有限元素混合法,柔度矩陣
 The twin-screw dry vacuum pump is widely used in low and medium-low vacuum applications. Its core element consists of a pair of rotors rotating in opposite direction on parallel axes. Usually one side of the rotor profile is a concave cycloid curve to prevent the inter-lobe leakage. Screw rotors are typically finished by the form grinding method. However, such concave rotor profile is almost impossible to grind on a conventional thread grinder by one tool due to severe undercutting and secondary enveloping problems. In this paper we propose a novel Tilt Form Grinding (TFG) method to overcome the problem of concave profile grinding. By using this proposed machine arrangement, the concave rotor profile can be ground without undercutting and secondary enveloping. Further, the right-hand and left-hand screw rotor can be manufactured by the same tool when only one rotational direction in tilt angle. Numerical examples are presented to validate the proposed TFG method. The rotor of twin-screw vacuum pump with uniform pitch can be ground by form grinding tool, but the one with variable pitch not. Thus, manufacturing the screw rotor with the variable pitch by CNC Lathes is proposed. The initial position and trajectory of turning tools and the manufactured profile error of screw rotor are derived and verified numerically. According to the simulation results, the proposed CNC turning process is feasible. However, further experiments are still required to check the tool life and machining accuracy.The screw rotor of vacuum pump works rely on a pair of timing gears, some clearances between the rotors are required. The lock-up and interference between the rotors are caused by the gear fatigue failure. So the priority will be the calculation of contact stress of the gears. In this paper, the Hybrid Finite Element Method (HFEM) combined with the Tooth Contact Analysis (TCA) was applied to solve the static contact stress problem of the meshing cylindrical gear set. Using the examples in this study, the contact stress of the meshing gears was calculated and compared with the result of ANSYS in order to validate the proposed HFEM method. Furthermore, the proposed HFEM in this study can also be used to determine the amount of tooth surface modification.Keywords:Screw rotor, Variable pith, Tilt form grinding method, Hybrid finite element method, Compliance matrix
 中文摘要 IABSTRACT IIIACKNOWLEDGEMENTS(致謝) VTABLE OF CONTENTS VILIST OF FIRURES IXLIST OF TABLES XIVNOMENCLATURE XVCHAPTER 1 INTRODUCTION 11.1 RESEARCH OBJECTIVE 11.2 LITERATURE REVIEW 41.3 THESIS OUTLINE 9CHAPTER 2 THE STUDY ON TURNING PROCESS OF THE VARIABLE-PITCH TWIN-SCREW VACUUM PUMP BY CNC LATHES 122.1 THE MATHEMATICAL MODEL FOR TURNING THE SCREW ROTOR OF VACUUM PUMP 122.1.1 The mathematical model of the tooth profile of the rotors 122.1.2 The mathematical model of manufacturing the rotor by turning 152.2 THE CURVE WITH VARIABLE PITCH OF THE SCREW ROTOR 172.3 THE ARRANGEMENT OF THE TURNING INSERTS 202.4 THE CALCULATION OF THE FINISHED ERROR 242.5 NUMERICAL EXAMPLES AND DISCUSSIONS 262.5.1 The arrangement of the insert of the rotor with uniform pitch 262.5.2 The arrangement of the insert of the rotor with variable pitch 272.5.3 The arrangement of the rotor with variable pitch by using the larger insert 292.6 SUMMARY 31CHAPTER 3 A NOVEL TILT FORM GRINDING METHOD FOR THE ROTOR OF DRY VACUUM PUMP 603.1 MATHEMATICAL MODELS OF THE TFG METHOD 603.1.1 Mathematical model of the grinding wheel using the TFG method 613.1.2 Mathematical model of the ground rotor profile using the TFG method 653.2 CALCULATION OF THE MINIMUM TILT ANGLE 673.2.1 Conventional form grinding process without tilt angle 683.2.2 Minimum tilt angle to avoid undercutting and secondary enveloping 703.3 NUMERICAL EXAMPLES AND DISCUSSIONS 723.3.1 Transversal tooth profile of screw rotor is given 733.3.2 Axial section profile of form grinding wheel is given 753.3.3 Left and right rotors are ground by the same form grinding wheel 773.4 SUMMARY 79CHAPTER 4 CONCLUSION AND FURTHER WORKS 974.1 CONCLUSION 974.2 FURTHER WORKS 99APPENDIX A A STUDY OF THE CONTACT STRESS ANALYSIS OF CYLINDRICAL GEARS USING THE HYBRID FINITE ELEMENT METHOD 100A.1 MATHEMATICAL MODEL OF THE GEARS 101A.2 THE HYBRID FINITE ELEMENT METHOD (HFEM) 101A.2.1 Basic Assumptions 103A.2.2 Deformation compatibility and contact status decision condition 104A.2.3 Relative separation and continuity equations of contact pairs 106A.2.4 Solving the spur gear contact problem by the hybrid finite element method (HFEM) with tooth contact analysis (TCA) 114A.3 NUMERICAL EXAMPLES AND DISCUSSIONS 116A.3.1 Comparing the differences in computational time for FEM and HFEM 116A.3.2 Result of the static contact analysis of the spur gear 117A.3.3 Contact analysis of the cylindrical crown gear -- statistics 118A.4 SUMMARY 119REFERENCES 145PUBLICATION LIST 150VITA 152
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 1 利用有限元素混合法進行圓柱齒輪接觸應力分析之研究

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 1 戟齒輪齒面切削時間之研究 2 利用有限元素混合法進行圓柱齒輪接觸應力分析之研究 3 圓柱齒輪連續創成磨齒法之齒面修整研究 4 以齒輪幾何量測點資料進行虛擬單齒腹檢測技術之研究 5 齒輪磨齒機蝸桿砂輪重磨加工齒面精度研究 6 變導程真空幫浦轉子之製造方法研究 7 利用掃描式探頭量測未知齒形的圓柱齒輪 8 雙螺桿壓縮機轉子齒形及刀具之創新設計方法 9 以ANSYS分析雙圓弧螺旋齒輪接觸應力及齒形修型研究 10 戟齒輪切削刀具磨刀機數學模式推導之研究 11 戟齒輪切削共軛條件之研究 12 漸開線圓柱滾刀刀具量測 13 面滾式雙刀盤創成擺線形導程之螺旋齒輪研究 14 圓柱齒輪成型輪磨加工之數值模擬研究 15 蝸桿式砂輪齒形修整方法之研究

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