A New Method of the Positioning and Analysis of the Roughness Deviation in Five-Axis Milling of External Cylindrical Gear

Abstract

Five-axis milling is a modern, flexible and constantly developing manufacturing process, which can be used for the machining of external cylindrical gears by means of cylindrical end mills and special disc mills on universal multi-axis machining centres. The article presents a new method of positioning the tip and the axis of the end mill and the disc cutter in order to ensure a constant value of deviation of the theoretical roughness Rth along the entire length of the tooth profile. The first part presents a mathematical model of the five-axis milling process of the cylindrical gear and an algorithm for calculating the Rth deviation values. The next section describes the positioning of the end mill and the disc cutter. Then, a new method for the empirical determination of the distribution of the involute root angle Δui and the data description by means of the interpolation function are presented and described. In the conducted numerical tests, the influence of the geometrical parameters of the cylindrical gear on the deviation Rth is determined, assuming a constant Rth value in the five-axis milling process.

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

“…Cutting speed can reach up to 25–30 m/min with feed rate of 0.015 mm/blade. The advantage of this method is the possibility of machining arc fir tree slots [ 58 , 59 , 60 , 61 , 62 ].…”

“…Cutting speed can reach up to 25-30 m/min with feed rate of 0.015 mm/blade. The advantage of this method is the possibility of machining arc fir tree slots [58][59][60][61][62]. The use of a carbide broach increased the productivity approximately 2.5 time pared to HSS broach.…”

“…Cutting speed can reach up to 25-30 m/mi feed rate of 0.015 mm/blade. The advantage of this method is the possibility of mac arc fir tree slots [58][59][60][61][62]. Jianhua et al noticed that milling in a single machining pass may lead to sub the cutter to very high thermal loads and, as a result, accelerated tool wear (Figu Therefore, dividing the profile of the slot into a few parts and machining the subse sides and bottom of the slot was proposed [63][64][65][66].…”