Method for Optimizing the Tool and Process Design for Bevel Gear Plunging Processes.

Format:

Book

Author/Creator:

Mazak, Julia.

Series:

Ergebnisse aus der Produktionstechnik

Language:

English

Subjects (All):

Mechanical engineering.

Manufacturing processes.

Physical Description:

1 online resource (210 pages)

Edition:

1st ed.

Place of Publication:

Aachen : Apprimus Wissenschaftsverlag, 2021.

Summary:

For manufacturing bevel gears, a special tool system consisting of cutterhead and removable blades produces multi-flank chips which are of complex, three-dimensional geometry. The objective of this thesis was to optimize the manufacturing process for continuous and discontinuous plunging for bevel gear cutting regarding tool life based on tool angles and process parameters. For this purpose, a wear model was developed that is based on the elastic deformation of the workpiece.

Contents:

Intro

Table of Contents

Symbols and Abbreviations

1 Introduction

German Introduction

2 State of the Art

2.1 Manufacturing of Bevel Gears

2.1.1 Interaction of Geometry and Process Design

2.1.2 The Tool System for Soft Machining

2.1.3 The Process Chain for Conventional Manufacturing

2.2 Tool Failure for Machining with a Defined Cutting Edge

2.2.1 The Thermo-Mechanical and Tribological System Underlying Metal Cutting

2.2.2 Mechanisms of Tool Failure

2.2.3 Quantification of Tool Wear and Tool Life

2.3 Prediction of Tool Wear and Tool Life

2.3.1 Predictive Models

2.3.2 Investigations on Influencing Factors

2.4 Simulation Models for Analyzing Cutting Processes

2.4.1 Finite Element Method

2.4.2 Analytical and Hybrid Approaches

2.4.3 Geometric Penetration Calculation

2.5 Fundamentals of Statistics in Modeling

2.6 Conclusion

3 Objective and Research Hypothesis

4 Scientific Methodology

4.1 Trial Setup and Evaluation

4.2 Design of Experiments

4.3 System Boundaries

4.4 Model Setup

5 Development of Geometric-Kinematic Characteristics

5.1 Development of a Penetration Calculation Based on IntersectingPlanes

5.2 Validating the Simulation Results

5.3 Conclusion

6 Analysis of the Wear Behavior

6.1 Variation of Process Parameters at Reference Geometry

6.2 Variation of Tool Angles at Reference Process Parameters

6.3 Variation of Feed Ramps at Reference Geometry

6.4 Combination of Feed Ramps and Tool Angles

6.5 Conclusion

7 Verification of the Model's Parameters

7.1 Equivalence Tests for the Determined Parameters

7.2 Statistical Analysis of Feed Ramps

7.3 Conclusion

8 Application of the Tool Wear Model

9 Transfer of the Method to Continuous Plunging

10 Summary and Outlook

German Summary and Outlook

A Appendix.

A.1 Derivation of the Helix Equation for Feed Ramps

A.2 Results of the Simulative Process Analysis with BEVELCUT

A.3 Tool Wear for the Variation of Process Parameters at ReferenceGeometry

A.4 Tool Wear for the Variation of Tool Angles at Reference ProcessParameters

A.5 Tool Wear for the Variation of Feed Ramps at Reference Geometry

A.6 Tool Wear for the Combination of Feed Ramps and Tool Angles

B References.

Notes:

Description based on publisher supplied metadata and other sources.

Part of the metadata in this record was created by AI, based on the text of the resource.

ISBN:

9783863599805

3863599802

OCLC:

1257666280