Characterization of the Cutting Forces Generated During the Gear Hobbing Process: Spur Gear

Gear hobbing is a common method of manufacturing high precision involute gears. The thorough knowledge of the developed cutting forces and the wear of the cutting tool are of great importance in order to produce helical and spur gears as they influence the cost of the manufacturing process and the quality of the produced gear. A novel simulation code called HOB3D was created in accordance with the above. This code can simulate the complex movements involved in gear hobbing with the best available accuracy, which is achieved by embedding the developed algorithm in a commercial computer aided design (CAD) environment. The simulation code calculates and exports the total cutting forces as well as the cutting forces in every cutting edge involved in the cutting process.

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Characterization of the cutting forces and friction behavior in machining UD-CFRP using slot milling test

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-06544-8 ◽

2021 ◽

Vol 112 (11-12) ◽

pp. 3471-3483

Author(s):

Jamal Sheikh-Ahmad ◽

Fahad Almaskari ◽

Mohamed El-Hofy

Keyword(s):

Cutting Forces ◽

Friction Behavior ◽

Slot Milling

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Virtual Model of Gear Shaping—Part I: Kinematics, Cutter–Workpiece Engagement, and Cutting Forces

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4039646 ◽

2018 ◽

Vol 140 (7) ◽

Cited By ~ 10

Author(s):

Andrew Katz ◽

Kaan Erkorkmaz ◽

Fathy Ismail

Keyword(s):

Cutting Force ◽

Cutting Forces ◽

Spur Gear ◽

Cutting Edge ◽

Prediction Algorithm ◽

Force Model ◽

Time Step ◽

Solid Modeler ◽

Chip Geometry ◽

Gear Shaping

Gear shaping is, currently, the most prominent method for machining internal gears, which are a major component in planetary gearboxes. However, there are few reported studies on the mechanics of the process. This paper presents a comprehensive model of gear shaping that includes the kinematics, cutter–workpiece engagement (CWE), and cutting forces. To predict the cutting forces, the CWE is calculated at discrete time steps using a tridexel discrete solid modeler. From the CWE in tridexel form, the two-dimensional (2D) chip geometry is reconstructed using Delaunay triangulation (DT) and alpha shape reconstruction. This in turn is used to determine the undeformed chip geometry along the cutting edge. The cutting edge is discretized into nodes with varying cutting force directions (tangential, feed, and radial), inclination angles, and rake angles. If engaged in the cut during a particular time-step, each node contributes an incremental force vector calculated with the oblique cutting force model. Using a three-axis dynamometer on a Liebherr LSE500 gear shaping machine tool, the cutting force prediction algorithm was experimentally verified on a variety of processes and gears, which included an internal spur gear, external spur gear, and external helical gear. The simulated and measured force profiles correlate closely with about 3–10% RMS error.

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Effect of lead on the machinability of brass alloys using polycrystalline diamond cutting tools

The Journal of Strain Analysis for Engineering Design ◽

10.1177/0309324718796384 ◽

2018 ◽

Vol 53 (8) ◽

pp. 602-615 ◽

Cited By ~ 2

Author(s):

Luis Amaral ◽

Rafael Quinta ◽

Tiago E Silva ◽

Rui MB Soares ◽

Santiago D Castellanos ◽

...

Keyword(s):

Tool Wear ◽

Cutting Forces ◽

Cutting Tools ◽

Polycrystalline Diamond ◽

Chip Morphology ◽

Lead Free ◽

Production Techniques ◽

Polycrystalline Diamond Inserts ◽

Brass Alloys

The international safety regulations are pushing the manufacturers of water systems and equipment to remove lead from material compositions due to the potential human hazard of lead absorption. The usage of green lead-free brass alloys is becoming mandatory in many important markets, demanding the manufacturers to quickly adapt their production techniques both casting and machining to this new reality. Regarding machining, lead has been used to facilitate the chip control, working as a natural chip breaker and reducing the tool wear. Therefore, the reduction of lead composition in brass alloys contributes to a machinability decrease of the materials leading to higher cutting forces, long chips and higher tool wear. This work focuses on the machinability characterization of three different brass alloys (leaded, medium-leaded and minimally leaded) by means of cylindrical external turning process with polycrystalline diamond inserts. A parametric study covering three different depths of cuts, three feed rates and four cutting speeds was conducted for three brass alloys with two repetitions. Cutting forces, chip morphology and surface roughness were analysed and compared between alloys. Complementary microstructural and mechanical characterization of the alloys were performed. Analysis of variance was performed to analyse the results. Cutting forces, power consumption, specific cutting pressure, roughness and chip morphology identification were used as comparison criteria among the tested materials. Results have demonstrated the decrease of machinability with the lead reduction, with higher cutting forces and longer chips. Polycrystalline diamond tools used in this work could be a good option to overcome the machinability challenges of the lead-free brass alloys.

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Prediction of the cutting forces in gear hobbing and the wear behaviour of the individual hob cutting teeth

International Journal of Manufacturing Research ◽

10.1504/ijmr.2018.095376 ◽

2018 ◽

Vol 13 (4) ◽

pp. 342

Author(s):

Mattias Svahn ◽

Lars Vedmar ◽

Carin Andersson

Keyword(s):

Cutting Forces ◽

Wear Behaviour ◽

Gear Hobbing ◽

The Individual

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Influence of machining data on developed cutting forces in gear hobbing

International Journal of Machining and Machinability of Materials ◽

10.1504/ijmmm.2013.055121 ◽

2013 ◽

Vol 14 (1) ◽

pp. 66 ◽

Cited By ~ 1

Author(s):

Nikolaos Tapoglou ◽

Andreas Mammas ◽

Aristomenis Antoniadis

Keyword(s):

Cutting Forces ◽

Gear Hobbing

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Mechanics of Gear Hobbing

Journal of Engineering for Industry ◽

10.1115/1.3427692 ◽

1970 ◽

Vol 92 (1) ◽

pp. 103-108 ◽

Cited By ~ 2

Author(s):

A. Bhattacharyya ◽

S. R. Deb

Keyword(s):

Cutting Force ◽

Cutting Forces ◽

Radial Component ◽

Gear Hobbing

The exacting demands for producing accurate gears make it necessary to determine the cutting forces coming on the hob-shaft which is the weakest element subjected to severe bending and torsion. The authors, with the help of a specially designed hobbing dynamometer, have investigated the magnitude and nature of the tangential and radial component of cutting force during the conventional hobbing process.

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