scholarly journals 5-Axis Double-Flank CNC Machining of Spiral Bevel Gears via Custom-Shaped Milling Tools – Part II: Physical Validations and Experiments

2021 ◽  
Author(s):  
Gaizka Gómez Escudero ◽  
Pengbo Bo ◽  
Haizea González Barrio ◽  
Amaia Calleja Ochoa ◽  
Michael Barton ◽  
...  
Keyword(s):  
End Milling ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Flank Milling ◽  
Spiral Bevel Gear ◽  
Machining Accuracy ◽  
Machining Time ◽  
Milling Tool ◽  
Gear Manufacturing ◽  
Spiral Bevel

Abstract We investigate a recently introduced methodology for 5-axis flank computer numerically controlled (CNC) machining, called double-flank milling. Certain geometries, such as curved teeth of spiral bevel gear, admit this approach where the milling tool has tangential contact with the material block on two sides, yielding a more efficient variant of flank milling. To achieve high machining accuracy, the path-planning algorithm, however, does not look only for the path of the tool, but also for the shape of the tool itself. We validate the approach by series of physical experiments using an abrasive custom-shaped milling tool specifically designed for a particular type of a spiral bevel gear. We show the potential of this new methodology in the semifinishing stage of gear manufacturing, where it outperforms traditional ball end milling by an order of magnitude in terms of machining time, while keeping, or even improving, the machining error.

scholarly journals 5-axis double-flank CNC machining of spiral bevel gears via custom-shaped tools—Part II: physical validations and experiments

2021 ◽  
Author(s):  
Gaizka Gómez Escudero ◽  
Pengbo Bo ◽  
Haizea González-Barrio ◽  
Amaia Calleja-Ochoa ◽  
Michael Bartoň ◽  
...  
Keyword(s):  
End Milling ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Spiral Bevel Gear ◽  
Machining Accuracy ◽  
Machining Time ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Gear Manufacturing ◽  
Spiral Bevel

AbstractRecently, a new methodology for 5-axis flank computer numerically controlled (CNC) machining, called double-flank machining, has been introduced (see “5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools—Part I: Modeling and simulation”). Certain geometries, such as curved teeth of spiral bevel gear, admit this approach where the machining tool has tangential contact with the material block on two sides, yielding a more efficient variant of flank machining. To achieve high machining accuracy, the path-planning algorithm, however, does not look only for the path of the tool, but also for the shape of the tool itself. The proposed approach is validated by series of physical experiments using an abrasive custom-shaped tool specifically designed for a particular type of a spiral bevel gear. The potential of this new methodology is shown in the semifinishing stage of gear manufacturing, where it outperforms traditional ball end milling by an order of magnitude in terms of machining time, while keeping, or even improving, the machining error.

Research on the CNC Machining Simulation Model Build and Realize Based on the Spiral Bevel Gear with Forming Method

2010 ◽  
Vol 146-147 ◽  
pp. 770-774
Author(s):  
De Ji Hu ◽  
Qing Guo Meng ◽  
Wei Zhao
Keyword(s):  
Three Dimensional ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Solid Model ◽  
Spiral Bevel Gear ◽  
Machining Simulation ◽  
Spiral Bevel ◽  
3D Solid ◽  
Relationship Of ◽  
Gear Engagement

In view of the spiral bevel gear machined by the semi-generating means, a new method to create 3D solid model is proposed. The equation of tooth profile surface is deduced from the principles of spiral bevel gear engagement and cutting, according to the position relationship of the machine tool, the cutting tool and the workpiece, along with the cutting tooth process. Then the three-dimensional solid model of spiral bevel gear is developed with the delphi program using the known parameters and the above mathematic equations. The effectiveness of this method has been demonstrated.

Tooth crest chamfering method of spiral bevel gear using ball end milling cutter

2020 ◽  
pp. 095440542094975 ◽  
Author(s):  
Wei Wei ◽  
Zhe Li ◽  
Rao Tan
Keyword(s):  
End Milling ◽  
Bevel Gear ◽  
Tooth Surface ◽  
Feasible Region ◽  
Particle Swarm Algorithm ◽  
Spiral Bevel Gear ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Direction Angle ◽  
Spiral Bevel

A chamfering method is proposed in order to improve processing accuracy and efficiency of tooth crest chamfering of spiral bevel gear. Coordinates of discrete points of upper and lower edges of chamfering surface are calculated based on the mathematical model of tooth surface and face cone. Distances between center of ball end milling cutter and upper and lower edges are set equal to radius of the ball end milling cutter, chamfering tool path is generated by particle swarm algorithm solving, both sides of tooth crest can be chamfered simultaneously to ensure processing efficiency. Direction angle of the cutter axis is calculated based on the relationship between direction of the cutter axis and contact positions of the cutter surface. Aiming to prolong service life of cutter, direction angle varies uniformly within the feasible region and contact positions distribute evenly on the cutter surface. Pinion without tooth crest chamfering is installed on four-axis CNC machine tools, edge detector is used to detect axial and circumferential cutter positions, then chamfering experiment is completed. Widths of chamfering surface are measured on different measuring positions, maximum error is 0.08 mm compared with design width 1 mm which appears at tooth crest inner end of convex side. Measuring results show that chamfering error is much smaller than that with manual chamfering, which indicates that the chamfering method is feasible.

Characterization of Global Form Deviations for Spiral Bevel Gear and Correction of Machine-Setting Parameters

2011 ◽  
Vol 130-134 ◽  
pp. 616-620
Author(s):  
Zhong Si Xu ◽  
Lei Jin ◽  
Jin Tai Tian
Keyword(s):  
Least Square Method ◽  
Bevel Gear ◽  
Least Square ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Machining Accuracy ◽  
Global Form ◽  
Machine Setting ◽  
Spiral Bevel ◽  
Setting Parameters

In order to improve the machining accuracy of spiral bevel gear, difference surface was adopted to characterize its global form deviations quantifiably and correct its deviations. The quantitative mathematical relationship between the actual tooth surface deviations of spiral bevel gear and the corrected values of the machine-setting parameters had been referred, and the theoretical correction formula of the global form deviations had been gotten by the least square method. Finally, the pinion of spiral bevel gear in the automobile rear axle has been set for an example to account for the effectiveness of the deviation correction by use of the difference surface method.

Research on Milling Spiral Bevel Gear Using CТС Machine Tool

2011 ◽  
Vol 216 ◽  
pp. 345-349
Author(s):  
Yan Xia Du ◽  
Bao Zhan Lü ◽  
Feng Guo Bin
Keyword(s):  
Machine Tool ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Milling Simulation ◽  
Nc Milling ◽  
Spiral Bevel ◽  
3D Solid ◽  
Relationship Of

From the NC machining principle of spiral bevel gear, the motion relationship of machine tool, cutter and workpiece during machining spiral bevel gear was analyzed. Based on the machine coordinate system, the tooth surface equation and the cone equation of cutting edges of spiral bevel gear were put forward. 3D solid model of spiral bevel gear was constructed using Pro/E Wildfire2.0 software. The NC milling simulation was carried out by the VERICUT software, and at the same time, the experiment was researched. Simulation and experimental results show that the spiral bevel gear can adopt the method of CNC machining, and can ensure the high quality, especially for single or small batch production.

A Design Method for the Pinion of a Spiral Bevel Gear Drive Admitting Full Control on the Contact Area and the Transmission Error

2015 ◽  
Author(s):  
Baozhen Lei ◽  
Harald Löwe ◽  
Yuqiang Feng ◽  
Xunwei Wang
Keyword(s):  
Contact Area ◽  
Design Method ◽  
Transmission Function ◽  
Transmission Error ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Spiral Bevel Gear ◽  
Gear Drive ◽  
Full Control ◽  
Spiral Bevel

Two methods for the design of the pinion apposite to an existing spiral bevel gear are proposed. In both methods, the gear is given by a discrete or smooth parameterization, and the pinion is described in the same way, i.e. it can be produced on a CNC machining center without any further efforts. The first method gives full control on the position, direction, and the extent of the contact area of the pinion. The second method starts by choosing a quite arbitrary transmission function of the gear drive to be designed, and then gives full control on the position, direction, and the width of the contact area. Therefore, both methods provide much freedom in the design process.

Computerized Modeling and CNC Machining Simulation of Spiral Bevel Gear

2012 ◽  
Vol 482-484 ◽  
pp. 1081-1084
Author(s):  
Wen Jin Wang ◽  
Zhi Qiang Zhang ◽  
Jing Zhang ◽  
Jian Zhao ◽  
Ling Li Zhang ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Differential Geometry ◽  
Gear Tooth ◽  
Bevel Gear ◽  
Cnc Machining ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Hypoid Gear ◽  
Machining Simulation ◽  
Spiral Bevel

Based on the theory of gearing and differential geometry, a CNC hypoid generator mathematical model for spiral bevel has been developed. A mathematical model of a spiral bevel gear-tooth surface based on the CNC Gleason hypoid gear generator mechanism is proposed in the paper. The simulation of the spiral bevel gear is presented according to the developed machining mathematical model. A numerical example is provided to illustrate the implementation of the developed mathematic models.

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