0
Research Papers: Design of Direct Contact Systems

Machining Setting Optimization for Formate® Face-Hobbing of Bevel Gears With the Cutting Force and Tool Wear Constraints

[+] Author and Article Information
Mohsen Habibi

Mechanical and Industrial
Engineering Department,
Concordia University,
CAD/CAM Lab. EV 12.165,
1515 St. Catherine Street West,
Montreal, QC H3G 1M8, Canada
e-mail: mohs_hab@encs.concordia.ca

Zezhong Chevy Chen

Mechanical and Industrial
Engineering Department,
Concordia University,
CAD/CAM Lab. EV12.189,
1515 St. Catherine Street West,
Montreal, Quebec H3G 1M8, Canada
e-mail: zcchen@encs.concordia.ca

1Corresponding author.

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received January 6, 2016; final manuscript received June 13, 2016; published online July 13, 2016. Assoc. Editor: Hai Xu.

J. Mech. Des 138(9), 093301 (Jul 13, 2016) (9 pages) Paper No: MD-16-1006; doi: 10.1115/1.4033992 History: Received January 06, 2016; Revised June 13, 2016

Trial and error experiments are the dominant approaches to select machining settings and also cutting system design in face-hobbing of bevel gears. These time-consuming experimental tests impose undesired costs to industries. In the present paper, an integrated method is proposed to find optimum machining settings in face-hobbing based on minimum machining time and allowable cutting force and tool wear. Cutting blades in face-hobbing are converted to many infinitesimal oblique elements along the cutting edge, and the cutting forces and the tool wear are predicted on all these small elements. The constructed optimization problem seeks a face-hobbing scenario with minimum plunge time which meets the cutting force or crater wear depth constraints. The proposed method is applied in two case studies successfully to show the capability of the approach.

FIGURES IN THIS ARTICLE
<>
Copyright © 2016 by ASME
Your Session has timed out. Please sign back in to continue.

References

Usui, E. , Shirakashi, S. , and Kitagawa, T. , 1984, “ Analytical Prediction of Tool Wear,” Wear, 100(1–3), pp. 129–151. [CrossRef]
Wang, M. , Ken, T. , Du, S. , and Xi, L. , 2015, “ Tool Wear Monitoring of Wiper Inserts in Multi-Insert Face Milling Using Three-Dimensional Surface Form Indicators,” ASME J. Manuf. Sci. Eng., 137(3), p. 031006. [CrossRef]
Li, B. , 2012, “ A Review of Tool Wear Estimation Using Theoretical Analysis and Numerical Simulation Technologies,” Int. J. Refract. Met. Hard Mater., 35(1), pp. 143–151. [CrossRef]
Yen, Y. , Söhner, J. , Lilly, B. , and Altan, T. , 2004, “ Estimation of Tool Wear in Orthogonal Cutting Using the Finite Element Analysis,” J. Mater. Process. Technol., 146(1), pp. 82–91. [CrossRef]
Attanasio, A. A. , Ceretti, E. E. , Giardini, C. C. , and Cappellini, C. C. , 2013, “ Tool Wear in Cutting Operations: Experimental Analysis and Analytical Models,” ASME J. Manuf. Sci. Eng., 135(5), p. 051012. [CrossRef]
Attanasio, A. , Ceretti, E. , Fiorentino, A. , Cappellini, C. , and Giardini, C. , 2010, “ Investigation and FEM-Based Simulation of Tool Wear in Turning Operations With Uncoated Carbide Tools,” Wear, 269(5–6), pp. 344–350. [CrossRef]
Kuttolamadom, M. A. , Laine, M. M. , and Kurfess, T. R. , 2012, “ On the Volumetric Assessment of Tool Wear in Machining Inserts With Complex Geometries—Part 1: Need, Methodology, and Standardization,” ASME J. Manuf. Sci. Eng., 134(5), p. 051002. [CrossRef]
Kuttolamadom, M. A. , Laine, M. M. , Kurfess, T. R. , Burger, U. , and Bryan, A. , 2012, “ On the Volumetric Assessment of Tool Wear in Machining Inserts With Complex Geometries—Part II: Experimental Investigation and Validation on Ti-6Al-4V,” ASME J. Manuf. Sci. Eng., 134(5), p. 051003. [CrossRef]
Binder, M. , Klocke, F. , and Lung, D. , 2015, “ Tool Wear Simulation of Complex Shaped Coated Cutting Tools,” Wear, 330–331(1), pp. 600–607. [CrossRef]
Habibi, M. , and Chen, Z. , 2015, “ A New Approach to Blade Design With Constant Rake and Relief Angles for Face-Hobbing of Bevel Gears,” ASME J. Manuf. Sci. Eng., 138(3), p. 031005. [CrossRef]
Habibi, M. , and Chen, Z. , 2015, “ A Semi-Analytical Approach to Un-Deformed Chip Boundary Theory and Cutting Force Prediction in Face-Hobbing of Bevel Gears,” Comput. Aided Des., 73, pp. 53–65. [CrossRef]
Habibi, M. , and Chen, Z. , 2015, “ An Accurate and Efficient Approach to Undeformed Chip Geometry in Face-Hobbing and Its Application in Cutting Force Prediction,” ASME J. Mech. Des., 138(2), p. 023302. [CrossRef]
Stadtfeld, H. J. , 2014, Gleason Bevel Gear Technology: The Science of Gear Engineering and Modern Manufacturing Methods for Angular Transmissions, The Gleason Works, Rochester, NY, Chap. 2, 7, and 10.
Fan, Q. , 2005, “ Computerized Modeling and Simulation of Spiral Bevel and Hypoid Gears Manufactured by Gleason Face Hobbing Process,” ASME J. Mech. Des., 128(6), pp. 1315–1327. [CrossRef]
Altintas, Y. , 2012, Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design, Cambridge University Press, Cambridge, Chap. 2.
Ding, H. , and Shin, Y. C. , 2012, “ A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel,” ASME J. Manuf. Sci. Eng., 134(5), p. 051014. [CrossRef]
Islam, C. , Lazoglu, I. , and Altintas, Y. , 2015, “ A Three-Dimensional Transient Thermal Model for Machining,” ASME J. Manuf. Sci. Eng., 138(2), p. 021003. [CrossRef]
Ivester, R. W. , Kennedy, M. , Davies, M. , Stevenson, R. , Thiele, J. , Furness, R. , and Athavale, S. , 2000, “ Assessment of Machining Models: Progress Report,” Mach. Sci. Technol., 4(3), pp. 511–538. [CrossRef]
Lalwani, D. I. , Mehta, N. K. , and Jain, P. K. , 2009, “ Extension of Oxley's Predictive Machining Theory for Johnson and Cook Flow Stress Model,” J. Mater. Process. Technol., 209(12–13), pp. 5305–5312. [CrossRef]
Karpat, Y. , and Özel, T. , 2006, “ Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part I: Predictions of Tool Forces, Stresses, and Temperature Distributions,” ASME J. Manuf. Sci. Eng., 128(2), pp. 435–444. [CrossRef]
Iqbal, S. A. , Mativenga, P. T. , and Sheikh, M. A. , 2007, “ Characterization of Machining of AISI 1045 Steel Over a Wide Range of Cutting Speeds. Part 1: Investigation of Contact Phenomena,” Proc. Inst. Mech. Eng., Part B, 221(5), pp. 909–916. [CrossRef]
MAL Manufacturing Automation Laboratories, Inc., 2016, “CUTPRO(R),” University of British Columbia (UBC), Vancouver, Canada.
Gosselin, C., 2016, “HyGEARS V4.0,” Involute Simulation Softwares, Inc., Quebec, Canada.

Figures

Grahic Jump Location
Fig. 1

Nongenerated (Formate®) face-hobbing kinematics

Grahic Jump Location
Fig. 2

Crater depth for tests 1–5 (Table 3)

Grahic Jump Location
Fig. 3

Crater worn volume. Left: measured worn volume, wKT [8] (machining settings: ap = 3 mm, γn=−6deg, λs=0deg, κr=+90deg and f = 0.1 mm/rev); right: predicted average worn volume, w¯KT (present work).

Grahic Jump Location
Fig. 4

Displacement of the cutter head toward the workpiece (BO0−BO) with constant (const. acc.), linear (linear acc.), and optimized linear (opt. linear acc.) acceleration, respectively

Grahic Jump Location
Fig. 5

Predicted cutting forces for constant (const. acc.), linear (linear acc.), and optimized linear (opt. linear acc.) acceleration, respectively

Grahic Jump Location
Fig. 6

Maximum average tool wear rate, w¯˙max

Grahic Jump Location
Fig. 7

Left:Ttool life, tL; right: number of machined gears, nG

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In