Influence of tool wear on the component edge zone and component service life during 5-axis milling of large gears

 

Starting Situation

Complicated special toothing can be produced on universal milling machines with standard milling tools available at short notice. Due to the flexible kinematics, there are fewer restrictions with regard to realizable component geometries than is the case with conventional gear cutting processes. In the previous project it could be shown that spur gears with sufficient quality and load capacity can be produced by 5-axis milling. Based on the results of the previous project, however, it can be assumed that the tool condition will change significantly during the hard machining of a large gear. The effects of progressive tool wear on the marginal zone properties of gears have not yet been scientifically researched.

Research Objective

From the investigation of tools, which were used to detect an impairment of the edge zone, a tool wear criterion can be derived, which limits the tool life in an application-related and functional manner. In this context, a suitable measurement variable for tool wear during 5-axis gear milling will be determined. In order to increase process stability, it will be checked whether the tool wear can be reliably detected by the use of sensors in the process. Within the framework of the tool investigation, it is analysed how the milling cutter wear develops and from which machined volume or cutting path the derived wear criterion is reached. The aim of the project is to predict the influence on component integrity and thus on the load-bearing capacity by changing the tool condition for economically relevant component sizes.