Modelling of tool wear in gear hobbing with coated tools based on 3-axis milling investigations

摘要

The eternal goal increasing the productivity in gear manufacturing can be obtained, among others, by efficient process planning systems. Gear manufacturing is associated with complicated generating kinematics, chip formation and tool wear mechanisms. In the present paper the number of cuts per coated tool tooth in a generating position, up to the first substrate revelation and up to a flank wear width of 0.15 mm were predicted using appropriate coating Woehler-like diagrams; hereupon the developed maximum equivalent stress in the critical cutting edge region leading to film fatigue failure and subsequent flank wear was considered. The required data for these calculations were determined experimentally by 3-axis milling investigations. This method facilitates the simulation of gear hobbing chips in a less time-consuming way, compared to procedures with gear cutting kinematics. An application example for predicting the tool wear by the developed methodologies is presented.