Abstract
In this paper, a five-axis machining process is analyzed for large spiral-bevel gears, an interesting process for one-of-kind manufacturing. The work is focused on large sized spiral bevel gears manufacturing using universal multitasking machines or five-axis milling centers. Different machining strategies, toolpath patterns, and parameters are tested for both gear roughing and finishing operations. Machining time, tools’ wear, and gear surface are analyzed in order to determine which are the best strategies and parameters for large modulus gear manufacturing on universal machines. The case study results are discussed in the last section, showing the capacity of a universal five-axis milling for this niche. Special attention was paid to the possible affectations of the metal surfaces, since gear durability is very sensitive to thermo-mechanical damage, affected layers, and flank gear surface state.
Highlights
The large-sized spiral bevel gears represent one of the most important components of power transmission units in big machines, for mines and quarries, thermal power generation systems, marine propulsion elements, wind’s kinetic energy applications, and so on [1,2]
The software generated gear geometry, and was able to choose between the Gleason and Klingelnberg manufacturing methods for the spiral gears
After the large size gears that were produced in the five-axis milling universal machine, the main objective of the study was reached, which showed the capacity of the universal five-axis milling for this niche
Summary
The large-sized spiral bevel gears represent one of the most important components of power transmission units in big machines, for mines and quarries, thermal power generation systems, marine propulsion elements, wind’s kinetic energy applications, and so on [1,2]. Owing to the fact that there is presently an increase of energy requirements on the earth, the demand for large-sized spiral bevel gears has risen and future technology predictions have singled out that it may continue to do so for some time. Special gear cutting machines have traditionally manufactured these gears. In this regard, there are different methods for the gear-tooth surfaces generation. These methods are focused on medium and large batches production, for instance, gearboxes, cars transmissions, or outboard boats
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
