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TECHNICAL PAPERS

Gear Hobbing Cutting Process Simulation and Tool Wear Prediction Models

[+] Author and Article Information
K.-D. Bouzakis, S. Kombogiannis, A. Antoniadis, N. Vidakis

Laboratory for Machine Tools and Manufacturing Engineering, Mechanical Engineering Department, Aristoteles University, Thessaloniki 54006, Greece

J. Manuf. Sci. Eng 124(1), 42-51 (Mar 01, 2001) (10 pages) doi:10.1115/1.1430236 History: Received December 01, 1998; Revised March 01, 2001
Copyright © 2002 by ASME
Topics: Wear , Gears , Cutting
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References

Sulzer, G., 1974, “Leistungssteigerung bei der Zylinderradherstellung durch genaue Erfassung der Zerspankinematik,” Dissertation, TH Aachen.
Joppa, K. 1977, “Leistungssteigerung beim Waelzfraesen mit Schnellarbeitsstahl durch Analyze, Beurteilung und Beinflussung des Zerspanprozesses,” Dissertation, TH Aachen.
Tondorf, J., 1978, “Erhoehung der Fertigungsgenauigkeit beim Waelzfraesen durch systematische Vermeidung von Aufbauschneiden,” Dissertation, TH Aachen.
Bouzakis,  K.-D., 1979, “Ermittlung des zeitlichen Verlaufs der Zerspankraftkomponenten beim Waelzfraesen Teil 1: Digitalrechnerprogramm FRDYN,” VDI-Z, 121, No. 19, Oct., pp. 943–950.
Bouzakis,  K.-D., 1979, “Ermittlung des zeitlichen Verlaufs der Zerspankraftkomponenten beim Waelzfraesen Teil 2: Einfluesse technologischer Parameter der Werkzeuggeometrie und der Werkradgeometrie,” VDI-Z, 121, No. 20, Oct., pp. 1016–1026.
Bouzakis,  K.-D., 1980, “Konzept und technologishe Grundlagen zur automatiserten Erstellung optimaler Bearbeitungsdaten beim Waelzfraesen,” Habilitation, TH Aachen VDI-Z, 2 , No. 42.
Venohr, G., 1985, “Beitrag zum Einsatz von Hartmetall Werkzeugen beim Waelzfraesen,” Dissertation, TH Aachen.
Kauven, R. H., 1987, “Waelzfraesen mit Titannitridbeschichteten HSS-Werkzeugen,” Dissertation, TH Aachen.
Antoniadis, A., 1988, “Determination of the Impact Tool Stresses During Gear Hobbing and Determination of Cutting Forces During Hobbing of Hardened Gears,” Dissertation, Aristoteles University of Thessaloniki.
Gutman, P., 1988, “Zerspankraftberechnung beim Waelzfraesen,” Dissertation, TH Aachen.
Mundt, A., 1992, “Modell zur rechnerichen Standzeitbestimmung beim Waelzfraesen,” Dissertation, TH Aachen.
Bouzakis,  K.-D., and Antoniadis,  A., 1995, “Optimizing Tool Shift in Gear Hobbing,” CIRP Ann., 44, pp. 75–79.
Bouzakis,  K.-D., 1980, “Mathematische Beschreibung des Verlaufes des Werkzeugverschleißes beim Waelzfraezen. Teil 1: Untersuchungsmethoden und Kenngroeßen zur Erfassung des Werzeugverschleißes in den einzelnen Waelzstellungen,” VDI-Z, No. 20, Oct., pp. 857–868.
Bouzakis,  K.-D., 1980, “Mathematische Beschreibung des Verlaufes des Werkzeugverschleißes beim Waelzfraezen. Teil 2: Berechnung der Verschleißentwicklung in den einzelnen Waelzstellungen und beim Shiften; Programmkette Waelzfraeservershleiß,” VDI-Z, 122, No. 21, Nov. 1, pp. 951–965.
Bouzakis,  K.-D., and Koenig,  W., 1981, “Process on Models for the Incorporation of Gear Hobbing into an Information Center for Machining Data,” CIRP Ann., 30, pp. 77–82.
CemeCon GmbH, 1997, Informational Bulletins: Coating Services, Aachen.
Bouzakis, K.-D., Antoniadis, A., Kombogiannis, S., Orfanidis, N., Stamatiadis, Ch., and Vidras, A., 1998, “Determination of Tool Life Time in Gear Hobbing, to Increase the Productivity and to Reduce the Manufacturing Costs,” final report of PAVE project BE411, General Secretariat for Research and Technology, Ministry for Industry and Development of Greece.
Bouzakis,  K.-D., , 1998, “Experimental and FEM Analysis of the Fatigue Behavior of PVD Coatings on HSS Substrate in Milling,” CIRP Ann., 47, pp. 69–73.
Klocke,  F., , 1998, “Improved Cutting Processes with Adapted Coating Systems,” CIRP Ann., 47, pp. 65–68.
Bouzakis,  K.-D., Vidakis,  N., Kallinikidis,  D., Leyendecker,  T., Erkens,  G., Fuss,  H.-G., and Wenke,  R., 1998, “Failure Mechanisms of Multi- and Mono-Layer Physically Vapor Deposited Coatings in Interrupted Cutting Processes,” Surf. Coat. Technol., 108–109, pp. 526–534.
Bouzakis, K.-D, Kombogiannis, S., Antoniadis, A., Vidakis, N., and Anastopoulos, J., 1999, “Lifetime Prediction of PVD Coated HSS Tools in Gear Hobbing,” 1st International Conference THE Coatings, October, Ziti Ed., Thessaloniki pp. 139–158.
Bouzakis, K.-D, Kombogiannis, S., Antoniadis, A., Vidakis, N., and Anastopoulos, J., 1999, “Lifetime Prediction of PVD Coated Tools in Gear Hobbing,” 5th Conference on Machine Tools-Manufacturing Processes, December, Ziti Ed., Thessaloniki, pp. 224–245.
Bouzakis, K.-D, Kombogiannis, S., Antoniadis, and A., Vidakis, N., 1999, “Modeling of Gear Hobbing. Cutting Simulation and Tool Wear Prediction Models,” ASME International Mechanical Engineering Congress and Exposition, MED-Vol. 10, pp. 253–259.
Bouzakis, K.-D, Kombogiannis, S., Antoniadis, A., and Vidakis, N., 1999, “Modeling of Gear Hobbing. Cutting Simulation, Tool Wear Prediction Models and Computer Supported Experimental-Analytical Determination of the Hob Life-time,” ASME International Mechanical Engineering Congress and Exposition, MED-Vol. 10, pp. 261–269.

Figures

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Undeformed chip length l in various regions during hobbing versus the gear width, in a generating position
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The effect of chip geometry and shape (chip group) on the wear development
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Determination of chip group and equivalent chip dimensions in a generating position, with the aid of the FRSWEAR program
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Wear prediction in hobbing considering the chip formation at various cutting and individual generating positions
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Determination of the wear distribution at individual hob teeth considering the shift data
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The flow chart diagram to the developed FRSWEAR program
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Experimental procedure with modified fly hobbing kinematics, to monitor the wear development on hob teeth in individual generating positions
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Chip batches of various generating positions, with corresponding dimensions
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Wear progress and SEM photos of the hob tooth trailing flank
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Determination of the wear equation constant CVB as well as of the Chs,Cl and CAS ones
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Comparison between the achieved number of cuts up to a flank wear of 0, 3 mm in gear hobbing with uncoated and coated HSS tools in the cases of chips of the same group with different dimensions
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Comparison between the experimentally and the computationally derived wear progress in CAF fly hobbing
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Calculation of the wear development on certain hob teeth and the overall wear distribution over the hob teeth, calculated by means of the FRSWEAR program
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Flank wear development on the hob teeth at various shift conditions and gear widths
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Achieved overall gear width and number of cuts per hob tooth at various shift conditions and gear widths
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Achieved overall gear width per hob tooth with coated and uncoated tools
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Undeformed chip cross sections in entry, full cut and exit or transient cutting positions in gear hobbing
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Chip formation and typical chips at various tool generating positions in gear hobbing, as well as the corresponding analytically determined chip cross sections

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