Skip to main content
SpringerLink
Log in

Machinability improvement of gear hobbing via process simulation and tool wear predictions

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Typical processes of producing transmission gears involve hobbing, milling, or shaping of a forged stock to obtain the desired gear geometries. Among all these machining processes, gear hobbing is an efficient method of manufacturing high-quality gears. In this paper, a three-dimensional (3D) finite element model is presented to simulate the gear hobbing processes. The model is used to simulate the complicated kinematic motion between the hobbing tools and the gear workpieces and to perform a coupled thermo-mechanical analysis on the tools and the workpieces during the chip removal process. Cutting forces, torques, and temperature and stress distributions of the hobbing tools and workpieces are predicted using the proposed model. The tool wear progression in gear hobbing is analyzed in terms of tool geometry by a combined experimental-analytical method. The model considers the complex geometry of hob tooth profiles with multiple teeth engagement and can provide more insights into complicated gear hobbing processes. Based on the simulations with various tool geometries, a new tool geometry is arrived, which reduces spindle torque and shows a significant tool wear reduction. The modeling results are further validated through a direct comparison between the predicted and measured chip shape, torque, and tool wear rate.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Davis JR (2005) Gear Materials, Properties, and Manufacture. ASM International, Materials Park, OH, USA

    Google Scholar 

  2. Liu W, Ren D, Usui S, Wadell J, Marusich TD (2013) A gear cutting predictive model using the finite element method. Procedia CIRP 8:51–56

    Article  Google Scholar 

  3. Klocke, F., and Klein, A., 2006, “Tool Life and Productivity Improvement Through Cutting Parameter Setting and Tool Design in Dry High-Speed Bevel Gear Tooth Cutting,” Gear Technol., May/June, pp. 40–48

  4. Rech J (2006) Influence of cutting edge preparation on the wear resistance in high speed Dry gear hobbing. Wear 261:505–512

    Article  Google Scholar 

  5. Rech J, Djouadi MA, Picot J (2001) Wear resistance of coatings in high speed gear hobbing. Wear 250:45–53

    Article  Google Scholar 

  6. Vasilis D, Nectarios V, Aristomenis A (2007) “Advanced computer aided design simulation of gear hobbing by means of three-dimensional kinematics modeling”. ASME J Manuf Sci Eng 129:911–918

    Article  Google Scholar 

  7. Antoniadis A (1988) “Determination of the impact tool stresses during gear hobbing and determination of cutting forces during hobbing of hardened gears”, dissertation. Aristoteles University of Thessaloniki, Thessaloniki, Greece

    Google Scholar 

  8. Sinkevicius V (2001) Simulation of gear hobbing forces. Kaunas University of Technology Journal Mechanika 2:58–63

    Google Scholar 

  9. Antoniadis A, Vidakis N, Bilalis N (2002) “Failure fracture investigation of cemented carbide tools used in gear hobbing—part I: FEM modeling of Fly hobbing and computational interpretation of experimental results”. ASME J Manuf Sci Eng 124:784–791

    Article  Google Scholar 

  10. Antoniadis A, Vidakis N, Bilalis N (2002) “Failure fracture investigation of cemented carbide tools used in gear hobbing—part II: the effect of cutting parameters on the level of tool stresses—a quantitive parametric analysis”. ASME J Manuf Sci Eng 124:792–798

    Article  Google Scholar 

  11. Komori M, Sumi M, Kubo A (2004) “Method of preventing cutting edge failure of Hob due to chip crush”. JSME Int J Ser C 47:1140–1148

    Article  Google Scholar 

  12. Stein S, Lechthaler M, Krassnitzer S, Albrecht K, Schindler A, Arndt M (2012) “Gear hobbing: a contribution to analogy testing and its wear mechanisms,”. Procedia CIRP 1:220–225

    Article  Google Scholar 

  13. Stark S, Beutner M, Lorenz F, Uhlmann S, Karpuschewski B, Halle T (2013) Heat flux and temperature distribution in gear hobbing operations. Procedia CIRP 8:456–461

    Article  Google Scholar 

  14. Third Wave Systems Inc., 2014, Third Wave AdvantEdgeTM 6.2 User’s Manual, Minneapolis, USA.

  15. Marusich TD, Ortiz M (1995) Modelling and simulation of high-speed machining. Int J Num Meth Eng 38:3675–94

    Article  MATH  Google Scholar 

  16. Taylor, L. M. and Flanagan, D. P., 1987, “PRONTO 2D: a two-dimensional transient solid dynamics program” Technical Report No. SAND-86-0594, Sandia National Laboratories, Albuquerque, NM, USA

  17. Dimitriou V, Antoniadis A (2009) CAD-based simulation of the hobbing process for the manufacturing of spur and helical gears. Int J Adv Manuf Tech 41:347–357

    Article  Google Scholar 

  18. Bouzakis K-D, Kombogiannis S, Antoniadis A (2002) “Gear hobbing cutting process simulation and tool wear prediction models”. ASME J Manuf Sci Eng 124:42–51

    Article  Google Scholar 

  19. Usui E, Shirakashi T, Kitagawa T (1984) “Analytical prediction of cutting tool wear”. Wear 100:129–151

    Article  Google Scholar 

  20. Zhao H, Barber GC, Zou Q (2002) A study of flank wear in orthogonal cutting with internal cooling. Wear 253:957–962

    Article  Google Scholar 

  21. Yen Y, Söhner J, Lilly B, Altan T (2004) Estimation of tool wear in orthogonal cutting using the finite element analysis. J Mater Process Technol 246:82–91

    Article  Google Scholar 

  22. Lorentzon J, Jarvstrat N (2009) “Modelling the influence of carbides on tool wear”. Archives of Int J Comput Mater Sci Surf Eng 1:29–37

    Google Scholar 

  23. Ding H, Shen N, Shin YC (2012) Thermal and mechanical modeling analysis of laser-assisted micro-milling of difficult-to-machine alloys. J Mater Process Tech 212:601–613

    Article  Google Scholar 

  24. Pálmai Z (2013) Proposal for a new theoretical model of the cutting Tool’s flank wear. Wear 303:437–445

    Article  Google Scholar 

  25. Hindustan Machine Tools Limited, 2001, “Production Technology”, Tata McGraw-Hill Education, New York, NY, USA, pp. 325–335.

  26. Bianco Gianfranco, 29 December 2014, Dry Hobbing—more information (2), http://www.biancogianfranco.com/Agg%20Area%20UK/Hobs/Dry%20hobbing%20-%20more%20information%20(2).pdf

  27. Spittel, M., and Spittel, T., 2009, “Steel Symbol/Number: 34Cr4/1.7033,” Metal Forming Data of Ferrous Alloys - Deformation Behaviour, Landolt-Börnstein - Group VIII Advanced Materials and Technologies, Springer Berlin Heidelberg, pp. 996–1001.

  28. Matbase, 29 December 2014, 34Cr4 (High grade steel), http://www.matbase.com, /material-categories/metals/ferrous-metals/high-grade-steel/material-properties-of-high-grade-steel-34cr4.html#properties

  29. Metal Ravne, 29 December 2014, Steel VC130 (Mat.No. 1.7033, DIN 34Cr4, AISI 5132), http://www.metalravne.com/selector/steels/vc130.html

  30. eFunda, Inc., 29 December 2014, eFunda: properties of alloy steel AISI 5132, http://www.efunda.com/materials/alloys/alloy_steels/show_alloy.cfm?ID=AISI_5132&show_prop=all&Page_Title=AISI%205132

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Purdue University, West Lafayette, IN, 47907, USA

    X. Dong & Y.C. Shin

  2. Purdue Polytech Institute, Mechanical Engineering Technology, Purdue University, West Lafayette, IN, 47907, USA

    C. Liao & H.H. Zhang

Authors
  1. X. Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. C. Liao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Y.C. Shin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. H.H. Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Y.C. Shin.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Dong, X., Liao, C., Shin, Y. et al. Machinability improvement of gear hobbing via process simulation and tool wear predictions. Int J Adv Manuf Technol 86, 2771–2779 (2016). https://doi.org/10.1007/s00170-016-8400-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8400-3

Keywords

Search

Navigation