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Simulation Based Design for Large Module Gear Machining with Indexable Inserts

机译：具有可转位刀片的大模块齿轮加工的基于仿真的设计

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Production processes for large module gears are characterized by small batch sizes and high workpiece costs. Therefore, the production of scrap parts cannot be accepted. Manufacturing processes are often not pushed to their limits so that the limits themselves are often not clearly known. To use the potentials of modern tool and machine tool concepts, a deeper theoretical understanding of the processes is necessary. This applies especially to modern indexable insert gear cutting tools, which gain importance in these processes. In the past, gear cutting processes for large module gears have seldom been a subject of scientific research. Therefore, the design of these processes is largely based on experience. Especially, for the newer and more complex tool concepts using indexable inserts, a possibility to analyze processes theoretically is a key factor for deeper understanding of the processes and tool concepts. In this paper the two most important processes for green machining of large module gears, gear hobbing and form milling, are analyzed using simulation and machining trials. For the process simulation, major changes to existing process simulation tools for gear machining processes were implemented. For suitable machining trials, model processes were developed for milling and hobbing. These allow an analysis of the wear behavior of the tools based on a reduced number of machined parts. In this paper the bridge between simulation and machining for large module gears will be drawn in terms of chip removal and deformation, wear behavior and tool design features. As final result a first method for a simulation based process design will be given.
机译：大型模块齿轮的生产过程的特点是批量小，工件成本高。因此，废品的生产不能被接受。制造过程通常不会达到极限，因此常常无法清楚地了解极限本身。为了利用现代工具和机床概念的潜力，必须对过程有更深入的理论理解。这尤其适用于在这些过程中变得越来越重要的现代可转位刀片齿轮切削刀具。过去，大型模块齿轮的齿轮切割工艺很少成为科学研究的主题。因此，这些过程的设计很大程度上基于经验。尤其是，对于使用可转位刀片的更新且更复杂的工具概念，理论上分析过程的可能性是更深入地了解过程和工具概念的关键因素。本文通过仿真和加工试验分析了大型模块齿轮的绿色加工的两个最重要的过程，即滚齿和成型铣削。对于过程仿真，对齿轮加工过程的现有过程仿真工具进行了重大更改。为了进行适当的机加工试验，开发了用于铣削和滚齿的模型工艺。这些可以基于减少的机加工零件数量来分析工具的磨损行为。在本文中，将在切屑去除和变形，磨损行为和刀具设计特征方面绘制大型模块齿轮的仿真与加工之间的桥梁。作为最终结果，将给出用于基于仿真的过程设计的第一种方法。

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