Compensation of Geometric Deviations in 5-Axis-Milling of Gears: First Part Right Strategy for Gear Milling on Universal Machine Tools

摘要

5-Axis-Milling is gaining increasing importance in manufacturing, due to the high flexibility and the degrees of freedom in construction of gears and parts in general. Although the process is already used for years, the achievable tolerances for highly loaded bevel and helical gears do not yet match the high requirements needed. For economical production by 5-Axis-Milling the prevention of rejects is significant. As a result of the production of small batches and individual parts it is not possible to use measurement data to correct systematical deviations of components. Hence this report aims at stating a model for geometrical deviations in 5-Axis-Milling of gears. Therefore the types of deviations will first be specified and categorized. For the crucial deviations which occur during the manufacturing process, a prediction model will be developed, which can anticipate the appearing deviations. Using a compensation method this prediction model will correct the input data of the manufacturing process in order to realize first part right machining of gears.