An accurate and efficient approach to geometric modeling of undeformed chips in five-axis CNC milling

Chang, Zhiyong; Chen, ZezhongC.; Mo, Rong; Zhang, Dinghua; Deng, Qi

doi:10.1016/j.cad.2017.03.003

Cited by 9 publications

(7 citation statements)

References 30 publications

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“…A large amount of research has been undertaken in the area, resulting in efficient ways of simulating and predicting in cut characteristics. In the area of simulation of manufacturing processes, a series of approaches have been presented by researchers including analytical-, simulation-and experimentalbased models [6][7][8][9][10][11][12][13][14][15]. The most common simulation models include finite element and mathematical models.…”

Section: State Of the Artmentioning

confidence: 99%

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Tapoglou

2021

Machines

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Power skiving is a new gear cutting process that has been recognized to provide a step change in the production rate achieved in the machining of high-precision internal and external involute gears. The process is based on a continuous generating meshing between the workgear and the cutting tool. Understanding of the loads applied in the cutting tool, and therefore some of the sources of tool wear, have not been thoroughly understood. This paper presents a novel model that is able to predict with high accuracy the cutting forces in the power skiving process. The model is based on a solid modelling simulation algorithm that produces high-fidelity solid bodies that are used for the calculations. The results of the model have been experimentally validated. A series of process maps are also produced to assist in the identification of the optimal machining parameters.

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Section: State Of the Artmentioning

confidence: 99%

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Tapoglou

2021

Machines

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“…Contemporary investigations within the realm of gear research have predominantly centered on a variety of tooth contact mechanical performance evaluations, such as contact pressure, stress, and loaded contact pattern and transmission error [ 31 , 32 ]. However, some researchers [ 33 , 34 ] have restricted their investigations to singular evaluations of loaded meshing performance in isolation, thus inadvertently precluding a holistic assessment of the multifarious evaluation parameters, only separately considering one of the loaded meshing performance evaluations [ 35 ]. Moreover, in recent MOO designs for loaded meshing performances, the establishment of data-driven functional relationships has not been direct and efficient in terms of the final solution [ 36 , 37 , 38 ].…”

Section: Introductionmentioning

confidence: 99%

Data-Driven Multi-Objective Optimization Approach to Loaded Meshing Transmission Performances for Aerospace Spiral Bevel Gears

Zhou,

Shao,

Tang

2024

Materials

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Loaded meshing transmission performance optimization has been an increasingly significant target for the design and manufacturing of aerospace spiral bevel gears with low noise and high strength. An innovative data-driven multi-objective optimization (MOO) method is proposed for the loaded meshing transmission performances of aerospace spiral bevel gears. Data-driven tooth surface modeling is first used to obtain a curvature analysis of loaded contact points. An innovative numerical loaded tooth contact analysis (NLTCA) is applied to develop the data-driven relationships of machine tool settings with respect to loaded meshing transmission performance evaluations. Moreover, the MOO function is solved by using an achievement function approach to accurate machine tool settings output, satisfying the prescribed requirements. Finally, numerical examples are given to verify the proposed methodology. The presented approach can serve as a powerful tool to optimize the loaded meshing transmission performances with higher computational accuracy and efficiency than the conventional methods.

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“…Exksting research on flank milling is mainly about the minimization of machining errors. The corresponding issues include envelope surface [22][23][24][25], cutter-workpiece engagements [26][27][28][29][30], geometrical deviations [24,31,32], tool path planning strategies [33][34][35][36][37][38][39], tool path optimization with: particle swarm optimization method [40], dynamic programming method [41], local method [42], global method [43], constraints [44], generic cutters [45], the consideration of tool path smoothness [46], the influences of tool axis [47] and cutter runout [48,49], cutter optimization of shape [50] and size [51], etc. In contrast, the manufacturing of SBGs values the working performances [21], such as contact path and transmission errors.…”

Section: Introductionmentioning

confidence: 99%

An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

Xu¹,

Zhou

et al. 2021

Materials

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Five-axis flank milling has been applied in industry as a relatively new method to cut spiral bevel gears (SBGs) for its flexibility, especially for the applications of small batches and repairs. However, it still has critical inferior aspects compared to the traditional manufacturing ways of SBGs: the efficiency is low, and the machining accuracy may not ensure the qualified meshing performances. To improve the efficiency, especially for cutting non-ferrous metals, this work proposes an approach to simultaneously cut the tooth surface and tooth bottom by a filleted cutter with only one pass. Meanwhile, the machining accuracy of the contact area is considered beforehand for the tool path optimization to ensure the meshing performances, which is further confirmed by FEM (finite element method). For the convenience of the FEM, the tooth surface points are calculated with an even distribution, and the calculation process is efficiently implemented with a closed-form solution. Based on the proposed method, the number (or total length) of the tool path is reduced, and the contact area is qualified. Both the simulation and cutting experiment are implemented to validate the proposed method.

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An accurate and efficient approach to geometric modeling of undeformed chips in five-axis CNC milling

Cited by 9 publications

References 30 publications

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Data-Driven Multi-Objective Optimization Approach to Loaded Meshing Transmission Performances for Aerospace Spiral Bevel Gears

An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

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