Analysis and Optimization of Bevel Gear Cutting Processes by Means of Manufacturing Simulation - Simulation and Modeling Methodologies, Technologies and Application - page 268

In process 2, see figure 10 right, a cutting velocity of v c = 150 m/min and a feed
ramp of f BG = 0.16 - 0.10 mm per blade group was chosen. The cutter head with an
outer diameter D a = 165 mm was equipped with 14 carbide tools. Here the correlation
between the tool wear from cutting trial and the simulation is also good. The maxi-
mum tool wear occurred at the corner radius of the outside blade (OB) and the tip (T).
Even the tool wear in the corner radius of the inside blade (IB) can be determined by
the simulation. In this example the tool wear is similar in both corner radii compared
to process 1, where the amount of tool wear is very uneven. This tool wear behavior is
predictable with the simulation by means of the characteristic value K G .
In addition to full profile blades there is the concept of alternating half profile
blades. In order to show the good correlation between the cutting trial results and the
simulation results the tool wear and the characteristic value K G are presented for this
process, too,see figure 11.

Ring Gear Manufacturing (Process 3)

Outside Blade (OB) Inside Blade (IB)

150 150

75 75

0 0

OB Tip Tip IB

T

T

3 mm

3 mm

Fig. 11. Tool wear analysis of half profile blades

Here (process 3) the focus is not only the localization of the maximum tool wear at
the cutting edge but also the identification of the most critical blade regarding tool
wear. The maximum value for K G was calculated at the corner radius of the outside
blade (OB). This correlates well with the occurred tool wear from the cutting trials.
Even the lower tool wear of the inside blade (IB) was calculated correctly.

4.2

Tool Wear Analysis of Generating Process

Generally pinions are manufactured by a generating process. The tool and the work-
piece movement are coupled depending on the process kinematics. In process 4 a feed
ramp of v w = 8.72 - 12.4 °/s and a cutting velocity of v c = 230 m/min have been used.
The outer diameter of the cutter head has been D a = 268 mm and it was equipped
with 32 carbide full profile blades. In this process a generating from heel to toe is