Study of Machining of Gears with Regular and Modified Outline Using CNC Machine Tools

Abstract

Classic methods of machining cylindrical gears, such as hobbing or circumferential chiseling, require the use of expensive special machine tools and dedicated tools, which makes production unprofitable, especially in small and medium series. Today, special attention is paid to the technology of making gears using universal CNC (computer numerical control) machine tools with standard cheap tools. On the basis of the presented mathematical model, a software was developed to generate a code that controls a machine tool for machining cylindrical gears with straight and modified tooth line using the multipass method. Made of steel 16MnCr5, gear wheels with a straight tooth line and with a longitudinally modified convex-convex tooth line were machined on a five-axis CNC milling machine DMG MORI CMX50U, using solid carbide milling cutters (cylindrical and ball end) for processing. The manufactured gears were inspected on a ZEISS coordinate measuring machine, using the software Gear Pro Involute. The conformity of the outline, the tooth line, and the gear pitch were assessed. The side surfaces of the teeth after machining according to the planned strategy were also assessed; the tests were carried out using the optical microscope Alicona Infinite Focus G5 and the contact profilographometer Taylor Hobson, Talysurf 120. The presented method is able to provide a very good quality of machined gears in relation to competing methods. The great advantage of this method is the use of a tool that is not geometrically related to the shape of the machined gear profile, which allows the production of cylindrical gears with a tooth and profile line other than the standard.

Comparing the performance of uncoated insert and TiC insert in CNC novel machining of LDX 2101 duplex stainless steel for minimizing surface roughness

“…Taguchi L9 orthogonal array is a very apt tool to vary input parameters of CNC machines and find the range for surface roughness parameters and rate of material removal is the conclusion drawn over study made by [2]. In a study it is found that a coated carbide performs better than any uncoated insert during CNC machining process by using a workpiece of a particular grade EN36 steel alloy [3]. This research indicates an optimization strategy for CNC turning in IS2062 E250 steel employing carbide tools and it is carried out by [6].…”

“…There is a shortcoming in performance and correctness in conventional technique. To overcome these issues, CNC machines were introduced and played a major role in fabrication processes [1][2][3][4][5][6][7][8][9][10]. LDX2101 material was selected as the workpiece due to its anti-corrosive abilities and high hardness [1].…”

High precision optical measurement of involute tooth profile form deviation

“…Tooth profile deviation is an important index to evaluate the accuracy of gear and gear master. The traditional measurement of tooth profile deviation is completed by contact method [1] . With the continuous development of optical measurement technology, it provides a new research direction for the measurement of tooth profile deviation due to its advantages of high efficiency and no contact [2] .…”

The Mathematical Model of Curve-Face Gear and Time-Varying Meshing Characteristics of Compound Transmission

“…At the same time, in order to meet the requirements of high quality and low noise gear mass production, the quality control and accuracy detection of gear surface is particularly important. Golebski proposed a method to allow the production of cylindrical gears with a tooth and profile line other than the standard [36], and the comparsion of measuring methods for the involute profile of the spur gear tooth was described [37]. And the method of machining gears by the step-by-step method has been also proposed, which can be used in unit machining of large-module gears with an arbitrary profile modification system [38].…”