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Proceedings of CAD'16, 2016, 337-341
Numerical and Semi-analytical Simulation and Process Optimization of Face-hobbing of Bevel Gears Considering Cutting Forces and Tool Wear
Abstract. Rule-of-thumb based design for cutting tools and machining setting selection in face-hobbing of bevel gears cause cutting tool failures and workpiece accuracy issues. Lack of a virtual machining environment, to efficiently obtain the instantaneous un-deformed chip geometry and predict cutting forces in face-hobbing, results in undesirable production costs in industries. In the present paper, numerical and semi-analytical representation of the projection of the un-deformed chip on the rake face of the cutting blades is presented. The proposed approach is drastically fast and more accurate in comparison with numerical methods and can be implemented in a virtual gear machining environment. The cutting system intricate geometry, multi-axis machine tool kinematic chains and the variant cutting velocity along the cutting edge are taken into consideration to obtain the chip geometry efficiently. Then, cutting forces are predicted during face-hobbing by implementing oblique cutting theory using the derived chip geometry and converting face-hobbing into oblique cutting. Usui’s tool wear model is implemented in face-hobbing using the predicted cutting forces.
Keywords. Face-hobbing, Bevel Gears, Un-deformed chip, Cutting Forces, Virtual Machining, Process Optimization