Abstract
Gear shaping is the most important process for manufacturing internal gears. Even if this method is also suitable for the production of spur gears, these can be produced more effectively using hobbing. Gear shaping is also interesting for manufacturing of face-gears. Since the shaper cutter is quite simple compared to a hob and the tool costs are therefore relatively low, this method is particularly suitable for small series production. This manuscript deals with the simulation of gear shaping of face-gears with the aim of determining suitable process parameters such as radial and rotary infeed and thus achieving a stable manufacturing process as fast as possible and with low reject rate. The cutting forces are determined on the basis of the theoretical uncut chip thickness, whereby the tool deflection can be calculated using these, provided that the stiffness of the tool, machine tool and component holder is known. In addition, the tool wear can be estimated using a suitable wear model. Experimentally determined cutting forces during the shaping of a face-gear are used to validate the simulation model.
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