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Model of cutting forces prediction for gear milling considering the three-dimensional undeformed chip thickness, penetration curve and working angles

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Abstract

The cutting forces generated in gear milling are different from the cutting forces generated in milling and turning, due to the influence of the three-dimensional undeformed chip and penetration curve. To establish the cutting forces model to predict the cutting forces for gear milling, a mechanistic model considering three-dimensional undeformed chip thickness, penetration curve, and working angles is presented. In this paper, the calculation method for three-dimensional undeformed chip thickness is provided. In addition, the formula of penetration curve, a space curve of intersection of the sweep volume formed by the cutting edge and the outside cylinders of the workpiece, is obtained, which determines the machining zone. Moreover, the vector of resultant cutting speed is determined by vector analysis, on the basis of which, the working normal rake angle and working cutting edge inclination angle are determined. Furthermore, a gear milling cutter was used to carry out experiments to validate the cutting force model. The experimental results correlate in the predicted results and the errors of peak are around 20% in x-axis and y-axis. The main findings drawn from the experiments and simulations are that the peak of cutting forces of the down milling is higher than the peak of cutting forces of the up milling especially in the x-direction, due to the influence of the three-dimensional undeformed chip thickness.

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Data Availability

The datasets used during the current study are available from the corresponding author on reasonable request.

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Code availability

The code used during the current study is available from the corresponding author on reasonable request.

Funding

This work was supported by the National Natural Science Foundation of China (51775315), China and Key Technology Research and Development Program of Shandong Province, China (2019JZZY010114).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xiankang Tang, Jun Zhao & Zijian Zhang

  2. National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), Jinan, 250061, China

    Xiankang Tang, Jun Zhao & Zijian Zhang

Authors
  1. Xiankang Tang
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  2. Jun Zhao
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Contributions

Conceptualization: Xiankang Tang and Zijian Zhang. Methodology: Xiankang Tang. Resources: Jun Zhao. Writing—original draft: Xiankang Tang. Writing—review and editing: Jun Zhao

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Correspondence to Jun Zhao.

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Tang, X., Zhao, J. & Zhang, Z. Model of cutting forces prediction for gear milling considering the three-dimensional undeformed chip thickness, penetration curve and working angles. Int J Adv Manuf Technol 118, 1659–1671 (2022). https://doi.org/10.1007/s00170-021-07969-5

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