A prediction of cutting force, system vibration, and productivity in five-axis milling process of the spiral bevel gear

Abstract

In this study, Taguchi method and ANOVA that are applied to determine the influence of several input parametrs on cutting force amplitude (F), vibration acceleration amplitude (a), and machining productivity (P) in the five-axis finish milling process of the spiral bevel gear. Taguchi orthogonal L27 array is used to design the experimental matrix with 27 experiments. During finish milling process of the spiral bevel gear (X40 steel) with a ball-end mill cutter (HSLB-2030), the parameter that has most influence on F was spindle speed (37.51 %). The parameter that has the second influence degree on F was feed rate (22.97 %). The parameter that has the third influence degree on F was maximum scallop height (16.45 %). Toolpath strategy has negligible influence on F (less than 1 %). Feed rate was the most influence factor on a (22.48 %). The parameter that has the second influence degree on a was the maximum scallop height (21.73 %). The parameter that has the third influence degree on a was the toolpath strategy (3.65 %). Spindle speed has negligible influence on a (less than 1 %). The parameter that has the most influence on the P was the maximum scallop height (54.90 %). The parameter that has the second influence degree on P was the feed rate (18.92 %). The spindle speed and toolpath strategy have negligible influence on P (less than 1 %). Quadratic regression that is determined as the most suitable regression of F, a, and P in the finish milling process of the spiral bevel gear with the determination coefficients (R2) 86.72 % for cutting force amplitude, 93.46 % for vibration acceleration amplitude, and 99.85 % for machining productivity.