Optimal process parameters with regard to tool wear are generally selected based on experience. The parts of a defined geometry are machined until the tool life criterion is met. Subsequently, the resulting tool wear is analyzed and the process parameters are adapted accordingly. Due to the necessary iteration and an interruption of the production process, productivity decreases. Hence, the approach is time and cost consuming.
With the help of the manufacturing simulations, time and expenditure can be reduced. The optimal process parameters can be determined by analyzing the characteristic values for individual processes and a final cutting summary can be generated.
The manufacturing simulation BevelCut determines the common volume of the given blank and tool data by means of the machine and process kinematics through a penetration calculation based on intersecting planes. The thus determined volume correlates with the undeformed chip thickness. For each step in the process, the characteristic values such as chip thickness and chip length can be determined by analyzing the chip geometry. Currently, discontinuous plunging process with constant or varying feed are included.
The evaluation of the results can be done for the entire manufacturing process as well as for individual tool revolutions. In order to draw conclusions on the tool load, the determined characteristic values are depicted as a function of the unrolled profile edge.
The variation in load that a point on the cutting edge experiences can be analyzed by the number of cuts conducted. The chip thickness correlates with the load that is applied on the tool during the cutting process. The chip length describes the time of contact between cutting edge and part for one or several cuts. The chip volume represents the cut material for one individual point on the cutting edge. The effective technological clearance and rake angle allow to draw conclusions on the chip compression and flank wear.
By means of the resulting gear geometry deviations due to the manufacturing process can be analyzed. Furthermore, the flank geometry can be used as input data for a further tooth contact analysis.
Julia Mazak, M.Sc.
Tel.: +49 241 80-28472
Fax: +49 241 80-22293