Simulation of Hobbing for Analysis of Cutting Edge Failure Due to Chip Crush

Komori, Masaharu; Sumi, Masaoki; Kubo, Akiharu

doi:10.1115/detc2003/ptg-48068

Cited by 8 publications

(3 citation statements)

References 9 publications

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“…Among the numerous scientific papers devoted to this problem, several of them can be identified, in which the method and results of modelling the chip parameters in the hobbing process on the basis of 3D graphic reproduction of cutting element traces using CAD systems [1][2][3][4][5][6][7][8][9][10][11][12][13][14] are given. In these works, on the basis of the use of the possibilities of computer engineering graphics systems, the motion of the hob helical surface during rotation about its axis, as well as the cutting surface of a certain tooth, have been described.…”

Section: Review Of Modern Information Sourcesmentioning

confidence: 99%

Computer 3D modelling of chip geometry and force field in the hobbing process

Hrytsay¹,

Topchij²,

Kuk³

2018

Ukr. j. mech. eng. mater. sci.

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Nowadays, the main method of machining the gears with a module in the range 1-25 mm, which are integral parts of modern machines, remains hobbing. Operations of the toothed crown processing determine the efficiency of the entire technological process of manufacturing gears. Thus, the time expenses and performance, the cost of the gears, and their final quality depend to a large extent on these indicators in operations of hobbing. Considering the importance of this process for mechanical engineering, considerable attention of scientists is devoted to its modelling. Chip parameters are the key source of information required for comprehensive and complete analysis of the hobbing process. Despite the large number of publications devoted to this problem, there is still no methodology for adequate reproduction of these parameters. Known methods and models are characterized by significant simplifications and do not reproduce completely the kinematics of this complex process. This article presents a new approach to graphical modelling of the chip parameters in the hobbing process, which is based on the analysis and synthesis of elementary kinematic motions, related to unit motions and displacements of the hob cutting elements in the process of removing the metal in the gap between the teeth of the processed gear. The algorithm for forming the instantaneous transitional surface between the gear teeth and the threedimensional (3D) space geometry of the chips on all active teeth of the tool is implemented in the graphic system AutoCAD. The article presents the results of computer modelling of chips in the climb and up-cut hobbing with Archimedean and convoluted hobs. Complete information on the geometric structure of the cut layers provides the basis for complex and system modelling of this process at the level of separate racks, teeth and edge of a hob. In combination with the data on the intensity of plastic deformation, stresses and temperature obtained for the corresponding conditions of hobbing in the Deform system, data on the parameters of the cut layers create opportunities for predicting the heating and wear of cutting elements of a hob, their loading, strength of protective coatings, transient processes of the cutting force and temperature, designing of optimal technological processes of hobbing and management of these processes.

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Section: Review Of Modern Information Sourcesmentioning

confidence: 99%

Computer 3D modelling of chip geometry and force field in the hobbing process

Hrytsay¹,

Topchij²,

Kuk³

2018

Ukr. j. mech. eng. mater. sci.

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“…By this a maximum chip thickness of h cu,max = 20 lm and a cutting length of l cu,max = 4 mm occurs. To analyze the chip geometries and the local load on the cutting edge in geometrically complex gear cutting processes, geometrical penetration simulations were used [4][5][6]. The chip geometry was calculated using the penetration calculation SPARTApro developed at WZL [7,8].…”

Section: Research Objective and Approachmentioning

confidence: 99%

Gear finish hobbing: potentials of several cutting materials

Sari

Klocke

Löpenhaus

2015

Prod. Eng. Res. Devel.

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This paper deals with the investigation of gear finish hobbing using several cutting materials. Gear finish hobbing is a method for soft finishing of external cylindrical power transmission gears. Based on these results, the potential of the cutting materials cemented carbide, PM-HSS, cermet and PCBN were presented in this paper. The challenges in gear finish hobbing are small chip thicknesses and high cutting speeds. Regarding these points the wear behavior of the tools was investigated. For the investigation the fly-cutter process was used. In the conducted investigations the wear behavior at cutting speeds between 250 up to 2250 m/min was regarded. The conclusion is, cemented carbide tools have the highest potentials for gear finish hobbing at high cutting speeds. The cutting materials cermet and PCBN do not allow a stable process at cutting speeds above 1500 m/min.

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“…To analyze the chip geometries and the local load on the cutting edge in geometrically complex gear cutting processes, geometrical simulations are used [1][2][3][4][5]. The software SPARTA developed by Winter [2] is based on penetration calculation and enables to determine undeformed chip geometries in gear hobbing.…”

Section: Wear Model Developmentmentioning

confidence: 99%

Prognosis of the local tool wear in gear finish hobbing

Klocke

Gorgels

Weber

et al. 2011

Prod. Eng. Res. Devel.

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Gear finish hobbing is a method for soft finishing of external cylindrical power transmission gears. The application of this process is required when the process chain of gear production is to be set up completely free of coolant. Since this finishing technology is relatively new, there is some practical experience, but no fundamental knowledge regarding economical process design. One challenge in process design is that unbalanced tool wear typically leads to geometrical deviations of the machined gear profile. The aim of the investigations described in this paper is to develop a wear model which is capable to predict the local tool wear of gear finish hobbing tools. This model is based on analogy cutting trials and geometrical analyses of the chip geometries in gear finish hobbing. The results of the model are validated by flycutting trials with different local loads on the tool. The validation shows that an optimization of the local tool wear development can be achieved by means of the prediction model. Therefore, an optimization of the technological process parameters can be carried out based on this model to reach an efficient process design.

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Simulation of Hobbing for Analysis of Cutting Edge Failure Due to Chip Crush

Cited by 8 publications

References 9 publications

Computer 3D modelling of chip geometry and force field in the hobbing process

Computer 3D modelling of chip geometry and force field in the hobbing process

Gear finish hobbing: potentials of several cutting materials

Prognosis of the local tool wear in gear finish hobbing

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