Cemented carbide tools in high speed gear hobbing applications

CIRP Annals ◽  
2017 ◽  
Vol 66 (1) ◽  
pp. 117-120 ◽  
Author(s):  
B. Karpuschewski ◽  
M. Beutner ◽  
M. Köchig ◽  
M. Wengler
Keyword(s):  
High Speed ◽  
Cemented Carbide ◽  
Gear Hobbing ◽  
Cemented Carbide Tools

Fatigue Fracture Investigation of Cemented Carbide Tools in Gear Hobbing, Part 1: FEM Modeling of Fly Hobbing and Computational Interpretation of Experimental Results

2002 ◽  
Vol 124 (4) ◽  
pp. 784-791 ◽  
Author(s):  
A. Antoniadis ◽  
N. Vidakis ◽  
N. Bilalis
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Complex Geometry ◽  
High Speed Steel ◽  
Cutting Performance ◽  
Cutting Process ◽  
Cemented Carbide ◽  
Fem Modeling ◽  
Gear Hobbing ◽  
Cemented Carbide Tools

Gear hobbing is a highly utilized flexible manufacturing process for massive production of external gears. However, the complex geometry of cutting hobs is responsible for the almost exclusive utilization of high-speed steel (HSS) as cutting tool material. The limited cutting performance of HSS, even coated HSS, restricts the application of high cutting speeds and restricts the full exploitation of modern CNC hobbing machine tools. The application of cemented carbide tools was considered as a potential alternative to modern production requirements. In former investigations an experimental variation of gear hobbing, the so-called fly hobbing was applied, in order to specify the cutting performance of cemented carbide tools in gear production. These thorough experiments indicated that cracks, which were not expected, might occur in specific cutting cases, leading to the early failure of the entire cutting tool. In order to interpret computationally the reasons for these failures, an FEM simulation of the cutting process was developed, supported by advanced software tools able to determine the chip formation and the cutting forces during gear hobbing. The computational results explain sufficiently the failure mechanisms and they are quite in line with the experimental findings. The first part of this paper applies the verified parametric FEM model for various cutting cases, indicating the most risky cutting teeth with respect to their fatigue danger. In a step forward, the second part of the paper illustrates the effect of various technological and geometric parameters to the expected tool life. Therefore, the optimization of the cutting process is enabled, through the proper selection of cutting parameters, which can eliminate the failure danger of cemented carbide cutting tools, thus achieving satisfactory cost effectiveness.

Fatigue Fracture Investigation of Cemented Carbide Tools in Gear Hobbing, Part 2: The Effect of Cutting Parameters on the Level of Tool Stresses—A Quantitative Parametric Analysis

2002 ◽  
Vol 124 (4) ◽  
pp. 792-798 ◽  
Author(s):  
A. Antoniadis ◽  
N. Vidakis ◽  
N. Bilalis
Keyword(s):  
Parametric Analysis ◽  
Cutting Parameters ◽  
Cemented Carbide ◽  
Experimental Investigations ◽  
Tool Geometry ◽  
Technological Parameters ◽  
Manufacturing Method ◽  
Gear Hobbing ◽  
Cemented Carbide Tools ◽  
Selection Of

Gear Hobbing is a complex gear manufacturing method, possessing great industrial significance. The convoluted geometry of the cutting tools brings on modeling problems and is the main reason for the almost exclusive application of HSS as cutting material. However, despite its complicated kinematics, gear hobbing is sufficiently described by well-established software tools, which were presented in the first part of the present paper. Experimental investigations exhibited the cutting performance of cemented carbide cutting teeth, which were expected to be potential alternatives for massive hob production. In these cutting experiments, hardmetal tools exhibited in several cases early and unexpected brittle failures, which were interpreted by the FRSFEM model in the first part of the paper. This analysis indicated that the occurring dynamic stresses are the reason for the observed fatigue failures on the cemented carbide tools. The occurring stresses are highly dependent on the selection of cutting parameters and on the tool geometry. Therefore, the proper selection of the cutting data may prevent the early tool failures, as the dominant parameters for tool wear, allowing it to be worn out by the conventional abrasive mechanisms. Thus, the doubtless dominance of cemented carbide over the HSS tools, may be rendered. The present work illustrates a parametric analysis, which describes quantitatively the effect of various cutting and technological parameters on the stress level occurring in gear hobbing, with cemented carbide cutting teeth. Hereby, the optimization of the tool life is enabled, allowing the maximum exploitation of modern gear hobbing machine tools. Optimized gear hobbing with cemented carbide tools may be used, in order to introduce higher cutting speeds in massive gear production.

scholarly journals Study of the Processing of a Recycled WC–Co Powder: Can It Compete with Conventional WC–Co Powders?

2021 ◽  
Author(s):  
Alexandre Mégret ◽  
Véronique Vitry ◽  
Fabienne Delaunois
Keyword(s):  
High Speed ◽  
Raw Materials ◽  
Cemented Carbide ◽  
Full Density ◽  
Wet Milling ◽  
Vacuum Sintering ◽  
The Us ◽  
Milling Medium ◽  
Critical Minerals ◽  
Cemented Carbide Tools

AbstractCemented carbide tools suffer from many issues due to the use of tungsten and cobalt as raw materials. Indeed, those are listed by the European Commission as “critical raw materials” since 2011 and by the US Department of Interior as “critical minerals” in 2018. To remain competitive with the conventional high-speed steels, less performant but cheaper, WC–Co tools can be recycled. In the present paper, a WC–7.5Co powder, recycled by the “Coldstream” process, has been sintered with vacuum sintering. As preliminary experiments have shown that the sinterability of the powder is low, the sintering temperature was set at 1500 °C to achieve full density. In parallel, the influence of ball milling conditions (rotation speed and milling medium) on the reactivity of the recycled powder has been studied in terms of grain size distribution, hardness, and fracture toughness. The optimized milling conditions were found to be 6 h wet milling, leading to a hardness of about 1870 HV30 and a toughness of about 10.5 MPa√m after densification. The recycled powder can thus totally compete with conventional powders, opening avenues for the recycling of cemented carbide tools. Graphical Abstract

scholarly journals SURFACE ROUGHNESS AND ITS PREDICTION IN HIGH SPEED MILLING OF ALUMINUM ALLOYS WITH PCD AND CEMENTED CARBIDE TOOLS

2019 ◽  
Vol 2019 (04) ◽  
pp. 3136-3141 ◽  
Author(s):  
U. Teicher ◽  
S. Pirl ◽  
A. Nestler ◽  
A. Hellmich ◽  
S. Ihlenfeldt
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloys ◽  
High Speed ◽  
Cemented Carbide ◽  
High Speed Milling ◽  
Cemented Carbide Tools

scholarly journals HIGH SPEED GEAR HOBBING WITH CEMENTED CARBIDE HOBS

2014 ◽  
Vol 2014 (04) ◽  
pp. 527-532 ◽  
Author(s):  
B. Karpuschewski ◽  
M. Beutner ◽  
M. Wengler ◽  
M. Köchig
Keyword(s):  
High Speed ◽  
Cemented Carbide ◽  
Gear Hobbing

High Speed Turning of Ti-6Al-4V Alloy with Straight Cemented Carbide and PVD Coated Carbide Tools

2011 ◽  
Vol 496 ◽  
pp. 92-97 ◽  
Author(s):  
You Sheng Li ◽  
J. X. Deng ◽  
Steve Ebbrell ◽  
Michael N. Morgan ◽  
X.J. Ren
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Cemented Carbide ◽  
Linear Regression Method ◽  
X Ray ◽  
Multiple Linear Regression Method ◽  
Energy Dispersive Microanalysis ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Carbide Tools

This work comparatively studied the performances of straight cemented carbide tools and PVD coated carbide tools in high speed dry turning of Ti-6Al-4V alloy. Systematic machining tests have been performed and the tool life data were analysed using multiple linear regression method to establish extended Taylor tool life models. The wear mechanisms for both tools have been investigated in detail through SEM observation and X-ray energy dispersive microanalysis (EDS).

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