Achieving maximum efficiency (in terms of the quantity of products produced in a stipulated time) with improved accuracy and surface finish through chatter-free high-speed cutting processes are among the challenges of the current gear cutting industry. Modern techniques usually employ generating type of cutters, such as Fellow's gear-shaping cutter, for the production of high-speed lownoise accurate gears. A literature review has indicated that experimental and theoretical methods had been predominantly used in the design of gear cutting tools, compared with computer-aided methods. In this research a gear-shaping cutter for spur gears is modelled using three-dimensional ten-node tetrahedral finite elements. The stress values on the gear-shaping cutter are calculated at different instants of a cutting stroke, assuming different loading conditions. The analysis of stress distribution due to the varying force distribution on the gear cutter edges, for the same cutting and process parameters during the generation process, is believed to be new to the literature. NOTATION a design plane distance of a gear-shaping cutter from the rake face b total width of the cutter b c discarded width of the cutter b w working width of the cutter [B] matrix relating strains and displacements of an element D b base circle diameter [D] elasticity matrix feg Displacement vector h gp depth of cut (mm) [k] element stiffness matrix [K]global stiffness matrix m module of the gear shaper cutter (mm) P y,max maximum radial cutting force of the gear-shaping cutter P z,max maximum axial cutting force of the gear-shaping cutter fRg load vector fR int g internal load vector S kp rotary feed of the cutter in millimetres per double stroke S y , S z normal stresses in the gear-shaping cutter in the Y and Z directions respectively V cutting speed (m/min)
Achieving maximum efficiency (in terms of quantity of products produced in a stipulated time) with improved accuracy and surface finish through a chatter-free high-speed cutting process are problems of the modern gear cutting industry. Modern techniques employ a generating type of cutter such as Fellow's gear-shaping cutter for the production of high-speed noiseless and accurate gears. The literature review indicates that experimental and theoretical methods had been predominantly in use in the design of gear cutting tools as compared to the computer aided methods. In this research the gear-shaping cutter is modelled using three-dimensional ten-node tetrahedral finite elements. The research is carried out at the instant when the gear-shaping cutter plunges on the workpiece and the cutting forces during the generation process become maximum. The maximum three-dimensional displacements and stress values are generated under different cutting conditions. The effects of different cutting process parameters (speed, feed and depth of cut) on the maximum stress and deflection are studied in detail.
In the present investigation, first-order shear deformation theory (FSDT) is employed to conduct free vibration analysis of hybrid CNT-fiber nanocomposite conical shells using finite element approach. The effective material properties of this three phase nanocomposite is computed using Halpin- Tsai and Micro-mechanics model approach. The Lagrange’s equation of motion is used to derive the equilibrium equations of the rotating carbon nanotube – fibre nanocomposite conical shell wherein the nonlinearity due to rotation is also introduced. The Coriolis effect is neglected because of the moderate rotational speed of the shell. Finite element code is developed using eight noded isoparametric shell element and the same is validated with some literature to analyse the effect of twist angle, length to thickness ratio, aspect ratio, weight fraction of CNTs, and rotational speed on the fundamental frequency. The effect of such parameter on the mode shapes of the three phase nanocomposite shell are also presented here.
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