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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

Figures

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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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Undeformed chip cross sections in entry, full cut and exit or transient cutting positions in gear hobbing
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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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