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.

Copyright © 2016 by ASME
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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



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