5-axis double-flank CNC machining of spiral bevel gears via custom-shaped tools\u2014Part II: physical validations and experiments

Gaizka Gómez Escudero,Amaia Calleja-Ochoa,Luis Norberto López De Lacalle,Michael Bartoň,Haizea González-Barrio,Pengbo Bo

doi:10.1007/s00170-021-08166-0

Abstract

Recently, a new methodology for 5-axis flank computer numerically controlled (CNC) machining, called double-flank machining, has been introduced (see “5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools—Part I: Modeling and simulation”). Certain geometries, such as curved teeth of spiral bevel gear, admit this approach where the machining tool has tangential contact with the material block on two sides, yielding a more efficient variant of flank machining. To achieve high machining accuracy, the path-planning algorithm, however, does not look only for the path of the tool, but also for the shape of the tool itself. The proposed approach is validated by series of physical experiments using an abrasive custom-shaped tool specifically designed for a particular type of a spiral bevel gear. The potential of this new methodology is shown in the semifinishing stage of gear manufacturing, where it outperforms traditional ball end milling by an order of magnitude in terms of machining time, while keeping, or even improving, the machining error.

Highlights

Efficient and highly accurate manufacturing of curved geometries such as car transmissions, gearboxes, or other doubly curved engine parts is a serious challenge in many industries like automotive or aeronautic, to name a few
The purpose of this study is to further advance the recent geometric modeling simulations on 5-axis computer numerically controlled (CNC) machining with custom-shaped tools [10]
The results show that this approach outperforms classical ball end milling by order of magnitude in terms of machining time and, for the particular spiral bevel gear considered in this paper, this approach is well-suited for the semi-finishing stage

Summary

Introduction

Efficient and highly accurate manufacturing of curved geometries such as car transmissions, gearboxes, or other doubly curved engine parts is a serious challenge in many industries like automotive or aeronautic, to name a few. Spiral bevel gears, when compared to straight-toothed bevel gears, are able to run at higher speed [1] and are indispensable elements among gear mechanisms. To achieve smooth and silent high-speed transmission, manufacturing with a very high precision is essential, e.g., using direct face nanogrinding [2]. High precision increases durability of the manufactured gears that is another main objective for modern, sustainable manufacturing technologies [3]. Manufacturing of spiral bevel gears requires specially deviced machines. There are several mainstream approaches to manufacture spiral bevel gears: Extended author information available on the last page of the article

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Conclusion