Study on the analytical prediction of premier chipping in the involute gear-cutting process

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.

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

MATEC Web of Conferences ◽

10.1051/matecconf/201818403011 ◽

2018 ◽

Vol 184 ◽

pp. 03011 ◽

Cited By ~ 1

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 %.

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

International Journal of Process Management and Benchmarking ◽

10.1504/ijpmb.2020.104234 ◽

2020 ◽

Vol 10 (1) ◽

pp. 99

Author(s):

Kasinath Das Mohapatra ◽

Mantra Prasad Satpathy ◽

Susanta Kumar Sahoo

Keyword(s):

Cutting Process ◽

Gear Cutting

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A General Mathematical Model for Gears Cut by CNC Hobbing Machines

Journal of Mechanical Design ◽

10.1115/1.2828771 ◽

1997 ◽

Vol 119 (1) ◽

pp. 108-113 ◽

Cited By ~ 26

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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