A method for thermal characteristics modelling of hob assembly on dry hobbing machine

Liu, Zhitao; Tang, Qian; Li, Xianguang; Zou, Zheng; Yang, Yong

doi:10.1177/0954406218784619

Cited by 8 publications

(3 citation statements)

References 19 publications

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“…The thermal error of the spindle accounts for a nonnegligible proportion of the total machining error of precision machine tools. [1][2][3] A precision machine tool typically starts machining after preheating, and the thermal error can be eliminated by setting the tool before the machining begins. Therefore, the magnitude of the spindle thermal error has a negligible impact.…”

Section: Introductionmentioning

confidence: 99%

Feedback control of the mechanical spindle thermal error based on thermal simulation with bearing heat sources analysis

Lei

Gao

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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The thermal error stability (STE) of the spindle seriously affects the machining accuracy of a machine tool, however existing empirical heating model-based active cooling strategies mainly focus on suppressing the spindle’s overall thermal deformation and cannot effectively stabilize the thermal error. This study regards the “active cooling-spindle” system as a feedback control system and employs a data-driven thermal error model to provide feedback. Thus, the spindle thermal error can be stabilized for a long time owing to the homeostasis of the feedback control system under disturbance. A mechanical spindle with an external cooling scheme is taken as the study object. Bearings are the primary heat sources of the mechanical spindle; thus, the angular contact ball-bearing heat generation is precisely modeled based on local heat sources analysis of bearing components, elastohydrodynamic lubrication, and micro-contact theory. Thermal simulation of the spindle under varying-coolant temperature cooling is conducted to pre-validate the thermal error suppression and variation trend influencing effect, and obtain the Reference Input of Thermal Error (RITE) for the feedback control under different work conditions. Subsequently, a spindle thermal error feedback control system is developed, including computation, cooling, and real-time monitoring modules with inter-communication. Finally, the thermal error feedback control strategy is applied on the mechanical spindle, and experimental comparisons with constant coolant temperature cooling show that the thermal equilibrium time is advanced by 61.46%, 59.16%, 40.51%, and 58.08%. The thermal error variation range (TEVR) after the preheating stage is reduced to1.92, 1.52, 1.91, and 1.69 μm, respectively. The significant reduction in TEVR validated the effectiveness of the proposed strategy for spindle thermal error stabilization.

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Section: Introductionmentioning

confidence: 99%

Feedback control of the mechanical spindle thermal error based on thermal simulation with bearing heat sources analysis

Lei

Gao

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…Cao et al [14,15] established a heat source model for a high-speed dry hobbing machine and described the heat energy accumulation characteristics of the dry hobbing machine. Tang et al [16] revealed the temperature characteristics of the hob cutter assembly by quantifying the heat source of the dry hobbing machine. Kadashevich et al [17] proposed an improved DEXEL model capable of visualizing the temperature field and geometric characteristics of gears, which effectively reduces the thermal errors during gear machining.…”

Section: Introductionmentioning

confidence: 99%

Optimization of chip repose angle in dry hobbing machine considering minimum thermal accumulation on workbench

Yang

et al. 2022

Int J Adv Manuf Technol

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The thermal deformation problem is quite serious for the workbench of the environmental dry hobbing machine due to the thermal accumulation of hot chips. A better understanding of the quantity and optimization of the chip repose angle is quite necessary to reduce the workbench thermal deformation. Hence, this paper focuses on the chip repose angle modeling and optimization for the workbench of dry hobbing machine. Firstly, the dynamic flow characteristics of chips are clarified by analyzing the chip generation mechanism and the motion trajectory of dry hobbing. Then, the chip repose angle is mathematically characterized with consideration of the chip rolling characteristics, with which a chip repose angle optimization model is established by minimizing the thermal accumulation on the workbench, and a chip repose angle optimization method is proposed based on intelligent optimization algorithm. Finally, the effectiveness of the proposed method is analyzed through the simulation experiment on the dry hobbing of automotive reverse gear. The results show that the maximum overall thermal deformation is reduced by 8 μm for the workbench, and the skewness is reduced by 32% for the workbench spindle with the help of the proposed optimization method. The study provides an effective solution for the quantitative analysis and optimal design of chip repose angle on the workbench of the dry hobbing machine.

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“…However, the present work deals mainly with the prediction and compensation of thermal errors, forceinduced errors in the hobbing process and their coupling effects on the accuracy of hobbing. For instance, to study the coupling effects of thermal errors and force-induced errors on manufacturing precision during high-speed dry gear hobbing, the numerical simulations on the temperature distribution of the working devices, the force-induced errors and thermal errors generated in the gear hobbing process were performed by Li et al 16 Similarly, Liu et al 17 carried out a numerical simulation analysis under the conditions of steady-state and transient-state of the dry gear hobbing machine spindle assembly thermal deformation for predicting the temperature and deformation during gear machining. Sun et al 18 established models on gear hobbing geometric deviation prediction and optimisation based on a large number of hobbing experiments by using IPSO and BP algorithms to improve the accuracy of gear hobbing.…”

Section: Introductionmentioning

confidence: 99%

Modelling and experiment of gear hob tooth profile error for relief grinding

Yang

Chen

Wang

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Gear hob is an important tool that is most used in gear processing. Hob accuracy directly exerts an overwhelming influence on the quality of the processed gear. Generally, the hob tooth profile accuracy is mainly determined by relief grinding process. Studies on tooth profile errors of gear hobs caused by severe friction and cutting with the high-speed rotation of the wheel during the form grinding machining of hobs are limited. Thus, a theoretical model of the tooth profile error prediction under different machining parameters was established based on the analysis of coupling influence of high temperature and high strain rate on gear hobs in the relief grinding process. The model was completed on the basis of the dynamic explicit integral finite element method of thermo-mechanical coupling. Through the prediction model, the influence of the grinding depth ap, feed speed Vw and grinding speed Vs on the tooth profile error can be analysed. In addition, an algorithm for accurately calculate the grinding wheel axial profile by combining instantaneous envelope theory and hob normal tooth profile was proposed. The hob relief grinding experiments were carried out using the proposed grinding wheel profile algorithm. The relative error of the prediction obtained by comparing the calculation results of the prediction model with the experimental results is within 10%. Results prove the validity of the prediction model. This finding is greatly important for optimising the accuracy of hob relief grinding.

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A method for thermal characteristics modelling of hob assembly on dry hobbing machine

Cited by 8 publications

References 19 publications

Feedback control of the mechanical spindle thermal error based on thermal simulation with bearing heat sources analysis

Feedback control of the mechanical spindle thermal error based on thermal simulation with bearing heat sources analysis

Optimization of chip repose angle in dry hobbing machine considering minimum thermal accumulation on workbench

Modelling and experiment of gear hob tooth profile error for relief grinding

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