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Determination of cutting forces in Gear Shaping

Dandouti Emmanouela

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Summary

Gear Shaping is one of the most widely used gear cutting processes and is mainly applied for the creation of internal gears. A simulation model of the gear shaping process is going to be developed in the present thesis. The simulation code is going to be implemented in Visual Basic . NET based on Autodesk Inventor. Cases of helical and spur, external and internal gears are going to be studied.The main aim of the thesis is the calculation of the cutting forces developed during the process in different cases respecting the geometry of the gear, the geometry of the cutting gear and the cutting conditions. In order to achieve high accuracy both the cutting tool and the kinematics of the process are going to be modelled. The user of the simulation model will be able to choose the data input for the desired tool and workpiece geometry as well as the cutting conditions. Afterwards, the trajectory of the cutting tooth, that participates in the creation of a gear gap will be positioned according to the complex kinematics of the process.Finally, the dimensions of the undeformed chips are also going to be calculated, in order to estimate the components of the cutting forces. In order to verify the correctness of the model, the produced gear flanks are going to be compared to the theoretical ones, and the calculated cutting forces are going to be compared to the respective measured forces obtained from the literature.

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