Analysis and optimization of bevel gear cutting processes by means of manufacturing simulation

Abstract

When torque and speed are transmitted from a non-parallel orthogonal axle to another axle bevel gears are often used. They are applied e.g. in drive trains of automotive, ships and helicopters. The manufacturing of this gear type is often difficult due to unpredictable tool wear during the bevel gear cutting process. This leads e.g. to unexpected production stops for tool changes which results in undesired additional manufacturing costs. Currently it is not possible to analyze the bevel gear cutting process sufficiently, because of its complexity. Thus, cutting process design happens iteratively in order to find the optimum process parameters regarding high productivity and less tool wear. This issue leads to the demand for exact knowledge of the tool wear behavior. Due to this a manufacturing simulation for bevel gear cutting has been developed. During the simulation a modeling of the tool, workpiece and kinematics is performed as well as a geometrical penetration calculation. With this simulation approach different characteristic values for a detailed analysis are calculated. Within this paper the analysis and optimization of bevel gear cutting processes regarding tool wear are presented. Here, the calculated results from simulation have been compared to tool wear from experimental cutting trials.