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Research Papers

Manufacture of Spiral Bevel Gears Using Standard Profile Angle Blade Cutters on a Five-Axis Computer Numerical Control Machine

[+] Author and Article Information
Yi-Pei Shih

Department of Mechanical Engineering,
National Taiwan University of Science and
Technology,
No. 43, Sec. 4, Keelung Road,
Taipei 106, Taiwan
e-mail: shihyipei@mail.ntust.edu.tw

Can-Xun Zhang

Project Engineer Metal Forming
Technology Section,
Metal Industries Research and
Development Centre,
No. 1001 Kaonan Highway,
Kaohsiung 811, Taiwan

1Corresponding author.

Manuscript received July 1, 2016; final manuscript received January 20, 2017; published online March 6, 2017. Assoc. Editor: Xiaoping Qian.

J. Manuf. Sci. Eng 139(6), 061017 (Mar 06, 2017) (14 pages) Paper No: MANU-16-1359; doi: 10.1115/1.4035961 History: Received July 01, 2016; Revised January 20, 2017

Although face milling (FM) is a popular industrial cutting method for mass-producing bevel gears, current machines require many cutters with diverse profile angles to produce different gear types. In this paper, therefore, a flexible cutting method is proposed that eliminated the need of too many cutters for producing the gears with similar size and module by employing cutters with standard profile angle blades on a general five-axis machine. The settings for this machine are derived by mathematically modeling a virtual machine, after which the motion functions of the five-axis coordinates are determined through inverse kinematics. A sensitivity analysis is then performed to bring the tooth surface produced closer to its theoretical counterpart. The results of a cutting simulation confirm the correctness of this proposed method.

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Figures

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Fig. 1

Coordinate systems of a face milling cutter

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Fig. 2

Coordinate systems between the cutter and generating gear on a cradle-type bevel gear cutting machine

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Fig. 3

Coordinate systems between the generating gear and work gear on the cradle-type bevel gear cutting machine

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Fig. 4

Parameters of the original cutter surface

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Fig. 5

Cutter position in the coordinate system of the generating gear

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Fig. 6

Coordinate systems between the cutter and generating gear on the virtual machine

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Fig. 7

Coordinate systems for bevel gear cutting on the table-tilting type five-axis machine tool

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Fig. 8

Flow chart of the five-axis flank correction method for SBGs made by the SPABC

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Fig. 9

Positions of the original and SPABC cutter edges for the pinion

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Fig. 10

Simulated flank topographic errors using the numerical method: (a) pinion and (b) gear

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Fig. 11

Flank sensitivity topographies corresponding to the zero-degree polynomial coefficients for the five-axis movement

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Fig. 12

Flank sensitivity topographies corresponding to the first-degree polynomial coefficients for the five-axis movement

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Fig. 13

Part of the sensitivity matrix [Sij] for the polynomial coefficients of the five-axis coordinates

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Fig. 14

Simulated flank topographic errors after correction using the numerical method: (a) pinion and (b) gear

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Fig. 15

Position for cutting the convex frank of the pinion when ϕc=0 on the five-axis machine

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Fig. 16

Cutting simulation for the pinion using vericut

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Fig. 17

Flank topographic deviations produced using vericut simulation: (a) pinion and (b) gear

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