Optimization of Single Pitch Error and MRR in a WEDM Gear Cutting Process

2018 ◽  
pp. 285-312 ◽  
Author(s):  
Kasinath Das Mohapatra ◽  
Susanta Kumar Sahoo
Keyword(s):  
Cutting Process ◽  
Gear Cutting ◽  
Pitch Error

Stiffness Analysis of Gear Shaping Machine in Radial Direction With Gear Wheel-Cutter

2009 ◽  
Author(s):  
Petru A. Pop ◽  
Gheorghe Bejinaru-Mihoc ◽  
Ioan Olaru
Keyword(s):  
Machine Tools ◽  
Radial Direction ◽  
Gear Wheel ◽  
Cutting Process ◽  
Machining Process ◽  
Gear Cutting ◽  
Pitch Error ◽  
Shaping Process ◽  
Gear Shaping

The machining of cylindrical gears by gear shaping with gear wheel-cutter has accompanied of known cutting errors met at rolling gears cutting: pitch error, total pitch error, profile tooth error, circular runout, etc. The technical papers consider that two aspects can analyze gears shaping precision with gear wheel-cutter: first by the analysis of profile gear cutting errors, and second by profile gear cutting errors in “closing zone of teeth gear”, with a main factor according of stiffness machine tools. The analysis of stiffness machine has done with the values displacements and relative rotations of machine subassemblies to a fixed datum system and two mobile datum systems, in dependence of load applied during idle running or gear shaping process, could be defined three stiffness’s: static, quasi-static and dynamic stiffness. During the cutting process, the variation predictable distance between cutter axe and wheel-workpiece axe is important. This study is carrying out by stiffness machine analysis in radial direction of OY axe. The paper has proposed a method of quasi-static stiffness machine determination of gear shaping process with wheel-cutter. During cutting process occurs altering positions between subassemblies of ram-toolholder and rotated table, even is used finishing working conditions. The research has done by an integration system “force-displacement”, formed by a dynamometer adaptable of gear machine-MD 250, which allowing the acquisition of cutting forces on three axes and displacements of ram-toolholder-workpiece during machining process. The measurement has done in “closing zone of gear”, respectively the outside of that, due to determination of stiffness machine tools. In addition, this research presented the assessing of working accuracy of gear shaping machine with gear wheel-cutter.

Modeling and Analysis of Wire EDM in a Gear Cutting Process for a 2D Model

2018 ◽  
Vol 5 (2) ◽  
pp. 4793-4802 ◽  
Author(s):  
K.D. Mohapatra ◽  
V.B. Shaibu ◽  
S.K. Sahoo
Keyword(s):  
Cutting Process ◽  
Wire Edm ◽  
Modeling And Analysis ◽  
Gear Cutting ◽  
2D Model

Optimization of Cutting/Tool Parameters for Dry High-Speed Spiral Bevel and Hypoid Gear Cutting with Cutting Simulation Experiment

2012 ◽  
Vol 472-475 ◽  
pp. 2088-2095 ◽  
Author(s):  
Gan Hua Liu ◽  
Hong Zhi Yan ◽  
Jun Jie Zhang
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Process ◽  
Hypoid Gear ◽  
Gear Cutting ◽  
Relief Angle ◽  
Spiral Bevel

Tool life and the rationality of cutting parameter setting are evaluated directly by cutting force. In order to predict cutting force, and then to optimize the tooth cutting condition for dry high-speed spiral bevel and hypoid gear cutting, this study has established a 2D cutting FEM simulation platform by using DEFORM-2D based on the 2D orthogonal slot milling experiment. Through the platform, using the method of combining single-factor experiment and multi-factor orthogonal experiment, this study has explored the influence of cutting/tool parameters on cutting force in the dry high-speed cutting process of 20CrMnTi spiral bevel and hypoid gear (face hobbing dry cutting process). The results show that from high degree to low degree, the influence of each parameter on cutting force is as follows: feed > cutting speed > relief angle(P.A.side) >blade rake angle, and the influence of the first three parameters is significant, the influence of blade rake angle is not significant; the optimized condition for dry high-speed spiral bevel and hypoid gear cutting is suggested to be: the cutting speed is 300 m/mim, the feed is 0.06 mm/r, the blade rake angle is 14° and the relief angle(P.A.side) is 10°; the cutting edge can be honed moderately, but the hone radius is not bigger than 0.1 mm.

scholarly journals Analysis of the tool life of coated hob milling tools for gear cutting of cylindrical gear

2018 ◽  
Vol 184 ◽  
pp. 03011 ◽  
Author(s):  
Sandra Sovilj-Nikić ◽  
Bogdan Sovilj ◽  
Gyula Varga ◽  
Nicolae Ungureanu ◽  
Vladimir Blanuša
Keyword(s):  
Tool Life ◽  
Production Equipment ◽  
Cutting Process ◽  
Cylindrical Gear ◽  
Process Improvements ◽  
Cylindrical Gears ◽  
Gear Cutting ◽  
Milling Tool ◽  
Continuous Demand ◽  
Milling Tools

The improvement of the gear cutting process by hob milling is also significant for the producers of gears as well as for the producers of hob milling tools. Due to the complexity of the process, the high values of the gears, and in particular the hob milling tool, the research of the bases for optimizing the process of gear cutting by hob milling requires significant financial resources and significant efforts of the researchers. In the modern production of gears there is a continuous demand for increasing the economy. In the gear cutting process improvements of the production equipment and materials for the cutting elements of the hob milling tools are necessary. In this paper an analysis of the tool life of coated hob milling tools for gear cutting of cylindrical gears is given. The experimental results have shown that the hob milling tools with inserted combs coated with TiAlN outperform the hob milling tools with inserted combs coated with TiN. They have higher resistance of 60.6 %.

Optimisation of WEDM parameters in a gear cutting process using MOORA-based GA

2020 ◽  
Vol 10 (1) ◽  
pp. 99
Author(s):  
Kasinath Das Mohapatra ◽  
Mantra Prasad Satpathy ◽  
Susanta Kumar Sahoo
Keyword(s):  
Cutting Process ◽  
Gear Cutting

A General Mathematical Model for Gears Cut by CNC Hobbing Machines

1997 ◽  
Vol 119 (1) ◽  
pp. 108-113 ◽  
Author(s):  
Shinn-Liang Chang ◽  
Chung-Biau Tsay ◽  
Shigeyoshi Nagata
Keyword(s):  
Mathematical Model ◽  
Degree Of Freedom ◽  
Cutting Process ◽  
Generation Process ◽  
Cutting Mechanism ◽  
Gear Cutting ◽  
Different Types ◽  
General Mathematical Model ◽  
Crossed Axes ◽  
The Mathematical Model

A hobbing machine’s cutting mechanism is a mechanism with multi-degree of freedom during the cutting process. In this paper, we propose a general gear mathematical model simulating the generation process of a 6-axis CNC hobbing machine based on the cutting mechanism of CNC hobbing machine and worm-type hob cutter. The proposed gear mathematical model can be applied to simulate different types of gear cutting. Some examples are included to verify the mathematical model. Also, a novel type of gear named “Helipoid” which can be used in crossed axes transmission is proposed. The proposed general gear mathematical model can facilitate a more thorough understanding of generation processes and toward the development of novel types of gears.

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