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Study of the surface generation mechanism and roughness distribution in internal spline shaping in consideration of tool wear

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Abstract

Previous models for predicting the surface topography of internal splines do not consider the correlation between the tool and workpiece geometry and the cutter edge wear. In this work, considering the relationship between the tool and workpiece geometry, a model for the tooth topography of the internal spline is built via the micro-element method. A gear shaper wear model which consists of abrasive, adhesive, and diffusion wear is established based on the cumulative cutting distance of the cutter edge and the accumulation of undeformed chip thickness of the cutter edge micro-element. The distribution features of tooth topography are analyzed throughout an internal spline shaping experiment, which confirms the validity of the presented model. Moreover, a shaping process optimization algorithm is proposed through the advance-and-retreat method to obtain an even tooth topography and surface roughness. This work provides a reference for the prediction and optimization of the internal spline surface topography, which can enhance the integrity of the tooth surface and prolong the serviceable life of gear shaper.

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Code availability

The codes generated during the current study are available from the corresponding author on reasonable request.

Funding

This work was funded by Aero Engine Corporation of China’s 2019 Industry-University-Research Cooperation Project (No. HFZL2019CXY025), National Natural Science Foundation of Guangdong Province (No. 2023A1515010040), and National Key Laboratory of Science and Technology on Helicopter Transmission (Grant No. HTL-O-22G02).

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Authors and Affiliations

  1. School of Aerospace Engineering, Xiamen University, Xiamen, 361005, China

    Xiaofan Ma, Bin Yao & Zhiqin Cai

  2. Shenzhen Research Institute of Xiamen University, Shenzhen, 518000, China

    Zhiqin Cai

  3. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing, 210000, China

    Zhengminqing Li

Authors
  1. Xiaofan Ma
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  2. Bin Yao
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  3. Zhiqin Cai
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  4. Zhengminqing Li
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Contributions

Xiaofan Ma: methodology, data curation, formal analysis, validation, writing—original draft and editing. Bin Yao: funding acquisition, resources supervision, project administration, investigation. Zhiqin Cai: funding acquisition, writing—review, software. Zhengminqing Li: conceptualization, resources.

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Correspondence to Bin Yao or Zhiqin Cai.

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Ma, X., Yao, B., Cai, Z. et al. Study of the surface generation mechanism and roughness distribution in internal spline shaping in consideration of tool wear. Int J Adv Manuf Technol 128, 653–667 (2023). https://doi.org/10.1007/s00170-023-11772-9

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  • DOI: https://doi.org/10.1007/s00170-023-11772-9

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