Abstract
Free-form milling is a flexible gear machining method that allows the use of general disc cutters to machine various gear types on a 5-axis machine tool. This paper proposes a two-dimensional simulation method for free-form milling of cylindrical gears with disc cutters. A mathematical model for free-form milling of cylindrical gears with disc cutters is constructed. By analyzing the spatial positional relationships between the cutter and the workpiece, the instantaneous contact line is derived and projected onto the gear end face; then, the intersection of the projected curves is used to obtain the final profile. This calculation method enables rapid simulation of the actual cutting conditions on the gear end face, which helps determine the machining interference and analyze the tooth profile accuracy during the gear machining process. The method proposed in this paper can also be used to analyze the sensitivity of geometric position errors of the machine tool axes.
Highlights
Conventional machining methods, such as gear hobbing, form milling, require the tool to match the gear to be cut
Free-form milling is a novel and flexible gear machining technology that enables the flexible production of different types of gears on a general 5-axis machine with a general disc cutter
A simulation method is proposed for free-form milling
Summary
Xiaochuan Lin Nanjing Tech University School of Mechanical and Power Engineering. Keywords: Free-form milling, General disc cutters, Two-dimensional simulation method, Tooth pro le accuracy analysis. Version of Record: A version of this preprint was published at The International Journal of Advanced Manufacturing Technology on January 17th, 2022. Title page: A simulation method for free-form milling cylindrical gears with disc cutters Xiaomin Sun, Xiaochuan Lin, Rongjing Hong*,1,2. A simulation method for free-form milling cylindrical gears with disc cutters Xiaomin Sun, Xiaochuan Lin, Rongjing Hong*,1,2. By analyzing the spatial positional relationships between the cutter and the workpiece, the instantaneous contact line is derived and projected onto the gear end face, and the projected curves are intersected to obtain the final profile This calculation method realizes the rapid simulation of the actual cutting condition on the gear end face, which is beneficial to the judgment of machining interference and the analysis of the tooth profile accuracy during the gear machining process
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