As the most widely used cylindrical gear machining approach, gear hobbing owns characteristics of high efficiency but complexity. On the basis of generating theory, a series of cutting edges which regularly distributed on the basic worm face of the hob is going to remove material from the gear blank successively and the involute tooth flank is shaped by enveloping. The study on its forming principle can provide effective guidance for performance improvement. In allusion to the characteristics of multi-edge cutting, the spatial forming model for cylindrical gear hobbing is established. The parametric equation of cutting edges sequence is established based on the theoretical constraint relationship of the geometrical and structural parameters of the hob. The kinematics relationship between the hob and gear blank is determined according to geometric parameters of hob and gear as well as machining parameters. The parametric model of the spatial forming surface generated by the cutting edge sequence is derived. Based on the model, the geometry and thickness of the chip corresponding to each cutting edge is obtained with numerical method by discretization. And the dynamic main cutting force in gear hobbing process is calculated according to the chip geometry. The established model can be utilized to support parameter optimization of gear hobbing process and the geometric design of hob.
CHEN Yongpeng1
,
CAO Huajun1
,
LI Xianguang2
,
CHEN Peng2
. The Model of Spatial Forming with Multi-cutting-edge for Cylindrical Gear Hobbing and Its Application[J]. Journal of Mechanical Engineering, 2016
, 52(9)
: 176
-183
.
DOI: 10.3901/JME.2016.09.176
[1] BOUZAKIS K D, LILI E,MICHAILIDIS N,et al. Manufacturing of cylindrical gears by generating cutting processes：A critical synthesis of analysis methods[J]. CIRP Annals-Manufacturing Technology,2008,57：676-696.
[2] ABOOD A M. Dynamic analysis of the cutting forces in the gear hobbing[D]. UK：Newcastle University,2002.
[3] TAPOGLOU N,ANTONIADIS A. CAD-based calculation of cutting force components in gear hobbing[J]. Journal of Manufacturing Science and Engineering,2012,134(3)：031009-1-8.
[4] KOMORI M,SUMI M,KUBO A. Method of preventing cutting edge failure of hob due to chip cruch[J]. JSME International Journal Series C,2005,47(4)：1140-1148.
[5] BOUZAKIS K D,FRIDERIKOS O,TSIAFIS I. FEM supported simulation of chip formation and flow in gear hobbing of spur and helical gears[J]. CIRP Journal of Manufacturing Science and Technology,2008,1(1)：18-26.
[6] BOUZAKIS K. D,KOMBOGIANNIS S,ANTONIADIS A,et al. Gear hobbing cutting process simulation and tool wear prediction models[J]. Journal of Manufacturing Science and Engineering Transactions of the ASME,2002,124：42-51.
[7] TERASHIMA K,UENO T. Numerical analysis of hobbing in unfinished space[J]. Bulletin of JSME,1978,21(155)：907-914.
[8] TERASHIMA K,UENO T,HIDAKA K. Graphical analysis of hobbing in unfinished space[J]. Bulletin of JSME,1978,23(180)：983-990.
[9] 张金,黄筱调. 滚齿加工建模仿真及误差分析[J]. 机械设计,2009,26(4)：68-70.
ZHANG Jin,HUANG Xiaotiao. Modeling simulation and error analysis of gear hobbing machining[J]. Journal of Machine Design,2009,26(4)：68-70.
[10] 吴抗美,李芳. 滚齿过程数学模型的研究[J]. 吉林工业大学学报,1984(2)：102-112.
WU Kangmei,LI Fang. The research on themathematical model of gear hobbing process[J]. Journal of Jilin University of Technology,1984(2)：102-112.
[11] 冯显英,张承瑞,李沛刚,等. 齿廓三维滚切成形的运动数学模型[J]. 山东工业大学学报,1998,28(2)：139-143.
Feng Xianying,ZHANG Chengrui,LI Peigang,et al. Mathematical model for forming gear tooth profile with hobbing method[J]. Jounal of Shandong University of Technology,1998,28(2)：139-143.
[12] KIM D H. Geometry of hob and simulation of generation of the cylindrical gears by conventional or climb hobbing operation[J]. Proceedings of the Institution of Mechanical Engineers Part D：Journal of Automobile Engineering,2001,215(4)：533-544.
[13] DIMITRIOU V,ANTONIADIS A. CAD-based simulation of the hobbing process for the manufacturing of spur and helical gears[J]. International Journal of Advanced Manufacturing Technology,2009,41(3-4)：347-357.
[14] MUSTAFA G,ERSAN A,IHSAN K,et al. Investigation of the effect of rake angle on main cutting force [J]. International Journal of Machine Tools & Manufacture,2004,44：953-959.
