"FlexGear 2" – Influence of tool wear on the component-border zone and component life during 5-axis milling of gearing.

The results of the previous project IGF 17890 showed that significant tool wear occurs during 5-axis hard milling of large gearing. The state of the art shows that the tool wear influences the rim zone of the workpiece and therefore reduces the load capacity of the gearing. The goal of this project is to predict the influence of 5-axis milling on the component integrity and function on a commercially relevant scale. A hardened analogy component derived from relevant large gearing will be used during milling trials to produce tool wear. During this, the link between the cutting length, wear, and the process forces will be deduced. Afterwards, new and precisely pre-worn tools will be used to process type FZG-Cmod gearing. The manufactured gearing as well as the analogy components will be examined with regards to their geometry, surface, and rim zone quality. In order to assess the gearing’s performance potential with regards to its dependency on the tool’s condition, carrying capacity studies will be performed on the FZG-Cmod gearing.

To validate the results and apply them to real production, hard machining of large gearing will be performed in a random trial. Especially small and medium sized companies are faced with the task of manufacturing commercially viable high quality components, as well as to ensure the component’s performance capabilities. The sector of manufacturing gearing in small numbers is of great interest for these companies. The knowledge gained from this project serves to improve the understanding of tool wear, as well as the connected component impairment with regards to flank strength. Based on these findings, the hard machining by 5-axis mills will become a flexible and commercially viable manufacturing process for small quantities.