Contribution of Chip Deformations and Crushes to Tool Failures in High-speed Dry Gear Hobbing

Abstract

Abstract: In allusion to the chip deformations and chip crushes in high-speed dry gear hobbing, a simulation model of high-speed dry gear hobbing was built based on DEFORM-3D herein. Through the simulation of high-speed dry gear hobbing under different process parameters, the visualization of material removal processes in high-speed dry gear hobbing was achieved, and the mechanism of chip deformations and the tool wear conditions of dry hobs were obtained. Combined with experiments, the simulation results were further validated by comparing the chip geometry and tool damage types obtained from simulation and experiments respectively. This study may provide a reference for parameter optimizations and tool life extension in high-speed dry gear hobbing.

Key words: high-speed dry gear hobbing, chip deformation, chip crush, tool failure

摘要： 针对高速干切滚齿过程中切屑的形变规律及切屑挤压行为，基于DEFORM-3D建立了高速干切滚齿工艺仿真实验模型，通过对不同工艺参数下高速干切滚齿工艺实验仿真，实现了高速干切滚齿过程中齿轮材料去除过程的可视化，获得了高速干切滚齿过程中切屑的形变规律以及干切滚刀的磨损状态。结合实际高速干切滚齿加工实验，对比切屑形貌及干切滚刀损伤情况，进一步验证了切屑在生成及流动过程中的形变规律以及切屑对干切滚刀的挤压损伤行为。研究结果可为高速干切滚齿工艺参数优化以及高速干切滚刀的寿命延长和性能控制提供参考。

关键词: 高速干切滚齿, 切屑形变, 切屑挤压, 刀具损伤

CLC Number:

TG61

LI Benjie;CAO Huajun;YANG Xiao;ZHOU Jin. Contribution of Chip Deformations and Crushes to Tool Failures in High-speed Dry Gear Hobbing[J]. China Mechanical Engineering.

李本杰;曹华军;杨潇;周进. 高速干切滚齿工艺切屑形变规律及其对刀具的损伤行为[J]. 中国机械工程.

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