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CAD-based simulation of spiral bevel gear manufacturing processes and investigation of optimal process parameters

Efstathiou Charikleia

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Summary

The present doctoral dissertation focuses on the simulation of spiral bevel gear manufacturing processes. The ultimate goal of the study is to build the necessary simulation models for the optimization of the spiral bevel gear machining methods so that costly machining experiments can be avoided. The kinematics of the two most important spiral bevel gear machining processes, face milling and face hobbing, are simulated using BevelSim3D, an algorithm developed as part of this thesis. The algorithm models the blank gear, either pinion or crown, and cutting tool geometries, and creates the tool trajectory achieving the simulation of the process kinematics. As a result, the tooth flank generation and chip formation processes are revealed and the solid work gear and undeformed chip geometries are generated. The generated tooth flank topography can be used for further analysis to determine the effect of process parameters on tooth surface quality. To validate the simulation results, the BevelCurve3D algorithm is developed to compare the simulated tooth surface to the theoretical one. The validation process is carried out using a simple geometric approach by comparing the simulated with the theoretical 3D tooth surface coordinates and calculating the deviation between them. In addition to evaluating the surface topography, kinematic simulation can also be used to calculate the cutting forces that occur during the process. Utilizing the simulation results, the BevelForce3D algorithm calculates the cutting forces by analyzing the undeformed chip geometry. This is realized by dividing the solid chip geometry into elementary chips. Local cutting forces calculated on the revolving tip of the cutting blade can be used to predict tool wear, whereas global forces calculated at a fixed point on the work gear can be used to predict work gear deformation and specify the fixture type and clamping force that must be applied prior to machining. Finally, after the simulation and cutting forces algorithms are developed, several simulations are executed to investigate the effect of crucial cutting parameters on the quality of the simulated surface and the developed cutting forces. More specifically, the study revealed that generation feedrate has a major effect on the quality of both tooth flanks and finishing stock allowance, plunge feedrate and generation feedrate greatly impact the developed cutting forces.

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