Abstract
Machining of gears by 5-axis milling allows additional degrees of freedom in gear design compared to conventional hobbing processes. Changes in the machining technology influence the surface integrity and, thus, the service life of the machined gears. For this reason, different machining parameters were investigated regarding their effects on the surface layer and subsequently on service life. In this paper, the residual stresses and microstructures of a large gear manufactured by 5-axis milling and the service life of test gears are analyzed. With the results from this paper, the surface integrity and service life can be predicted depending on the machining parameters.
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