Abstract
The transient phenomenon of chip generations and behavior in the gear hobbing process are investigated by using a high-speed video camera. The chip behavior generated in gear finish hobbing process is very complicated and one can not identify each chip from specified cutting edges. The authors have built up a new simulation method of the hobbing process using a flying tool and a special-shaped workpiece, which consists of one tooth space. Visual evidences of the chip interference on the rake face and some conditions of contact between generated chips and the work surface were visually obtained. In the case of dry cutting conditon with a high-speed steel (HSS) flytool without coating on the rake face, the flytool cuts the workpiece frequently with the stuck chip generated in the previous revolution on the rake face. The newly generated chip pushes out the previous stuck chip, which flies away eventually. The chip flow on the rake face interferes strongly at the corner of the cutting edge when both top and side cutting edges produce different chips at the same time, and the chips flow out in changing the shape. The moving speed of the chip was also measured.
Highlights
Gear hobbing is one of the most complicated and severest cutting processes, which has peculiar characteristics of intermittent cutting with multi-cutting edges, producing different-shaped chips and having different situations of wear in every cutting edge, and being applicable in dry cutting conditions
Transition phenomenon of the hobbing process could not be observed yet due to high-speed phenomenon and being blocked out of sight by adjacent cutting edges
Observation of the chip generation and the chip flow has been a long-cherished dream among gear people
Summary
Gear hobbing is one of the most complicated and severest cutting processes, which has peculiar characteristics of intermittent cutting with multi-cutting edges, producing different-shaped chips and having different situations of wear in every cutting edge, and being applicable in dry cutting conditions. Transition phenomenon of the hobbing process could not be observed yet due to high-speed phenomenon and being blocked out of sight by adjacent cutting edges. Up to now, cutting transition information is estimated only by observation of cut-away chips and tool wear after hobbing. It is impossible to observe the transition phenomenon in the hobbing process because the target is blocked out of sight by adjacent cutting edges and it is the fate for the rotating multi-edge cutting tools. Using a high-speed video camera, the chip generation and the chip flow on the rake face of the flytool was successfully observed directly by high-speed image recognition for the first time. Measurement Technology and Intelligent Instruments IX observed and the moving speed of the chip on the rake face was measured by image processing. Discussions are given on the chip interference, the adhesion of the chip on the rake face, and the pressure bonding phenomenon among successive chips
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