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Analysis and Optimization of Bevel Gear Cutting
Processes by Means of Manufacturing Simulation
Christian Brecher
1
, Fritz Klocke
2
, Markus Brumm
1
, and Ario Hardjosuwito
1
1
Chair of Machine Tools, Laboratory for Machine Tools and Production Engineering (WZL),
RWTH Aachen University, Steinbachstr. 19, D-52074 Aachen, Germany
2
Chair of Manufacturing Technology,
Laboratory for Machine Tools and Production Engineering (WZL),
RWTH Aachen University, Steinbachstr. 19, D-52074 Aachen, Germany
{C.Brecher,M.Brumm,A.Hardjosuwito}@wzl.rwth-aachen.de,
F.Klocke@wzl.rwth-aachen.de
Abstract.
When torque and speed are transmitted from a non-parallel orthogon-
al 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 dif-
ferent 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.
Keywords:
Gear Cutting Simulation, Manufacturing Simulation, Bevel Gears,
Tool Wear Analysis.
1
Introduction
In general the transmission of torque or speed from one axle to a non-parallel ortho-
gonal axle is realized by bevel gears. Bevel gears are used in many applications like
in marine, in rear axles of automotive, in helicopters and industrial drives. The stan-
dard manufacturing of bevel gears is performed in a complex Computerized Numeri-
cal Control (CNC) cutting process. Due to unpredictable tool wear and sudden failure
of the cutting tools, unexpected production stops for tool changes occur and lead to a
loss of productivity, low process stability and finally to additional manufacturing
costs. Thus, the productivity of the machining process depends significantly on the
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