Search

Browse

• Communities
• Authors
• Year
• Titles
• Subjects

My Space

• Login

Optimization of gear shaping and power skiving cutting conditions

Marinakis Angelos

Full record

---

Summary

Gears are one of the most crucial machine elements, widely used in the industry, due to their capability to provide accurate, flexible and reliable rotary motion. Billions of gears are produced every year, while the global gear demand is growing constantly. While automotive industry is the primary consumer of gears, other industries also require huge amounts of gears such as the aerospace industry, agricultural machinery or power stations. As such, the optimization of gear manufacturing processes is a subject of great importance for the construction industry.Gear shaping and power skiving are some of the most characteristic gear cutting processes. Gear shaping is the primary process for manufacturing internal gears, while power skiving found application only recently with the development of five-axis CNC machines, greatly increasing productivity.The purpose of the current thesis is the development of a complete and reliable simulation model, which is embedded in a commercial CAD software, and is able to simulate the gear manufacturing processes of gear shaping and power skiving. The simulation model includes the creation of the cutting tool profile, the generation of the 3D trajectory of the cutting tool and the simulation of the complex kinematics of each manufacturing process. For the generation of the tool profile and trajectory, optimal discretization is used, which along with the high accuracy of the CAD software ensure the maximum accuracy of the model. Simulation results include the geometry of the final machined gear and the undeformed 3D chips generated during each manufacturing process. The geometry of the undeformed chips is used for the calculation of the developed cutting forces, which are then transformed in four different coordinate systems. For each gear manufacturing process, a graphical user interface is developed, in which a user may input process data, execute or store a simulation, but also view and export the simulation results.The verification of the simulation model is accomplished in three distinct stages. Initially the geometry of the gear gap flanks is validated through the comparison to the theoretical equations of the expected curves. The second stage involves the validation of the undeformed chip geometry. For the verification of the calculated cutting forces, the simulation results are compared to experimental results obtained from the literature.Finally, in order to analyze the effect of the cutting parameters of each cutting process, a series of simulations is executed for external and internal gear manufacturing. The results are used to derive the optimal cutting conditions for each process, regarding the effect of the parameters on the developed cutting forces.

Available Files

Services