MANUFACTURING SIMULATION OF BEVEL GEAR CUTTING - Simulation based Approach for Tool Wear Analysis

Christian Brecher, Fritz Klocke, Christof Gorgels, Ario Hardjosuwito

Abstract

The transmission of torque or speed from one axle to a non parallel orthogonal axle is realised by bevel gears. Bevel gears are applied in helicopters, in marine, in rear axles of automotives and industrial drives. The manufacturing of bevel gears is generally performed in a complex CNC cutting process. Due to unpredictable tool wear in bevel gear cutting, unexpected production stops e.g. for tool changes occur. This leads to additional manufacturing costs. Currently it is not possible to analyse the bevel gear cutting process sufficiently, because of its complexity. Hence, the design of the cutting process happens iteratively in order to find the best process parameters for a high productivity and optimal tool wear. Thus, an exact knowledge of the tool wear behaviour is necessary. Hence, a manufacturing simulation for bevel gear cutting has been developed at WZL. This simulation enables a detailed analysis of the process and consequently of the tool wear. Within this report a new approach for the tool wear analysis is presented. Four different gear cutting processes have been analysed regarding tool wear. The introduced new characteristic value KG, which is calculated by the simulation, has been compared to tool wear from cutting trials. All the presented investigations will be considered in a simulation-based tool life prediction model which will be developed within a project funded by the German Research Foundation (DFG).

References

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Paper Citation


in Harvard Style

Brecher C., Klocke F., Gorgels C. and Hardjosuwito A. (2011). MANUFACTURING SIMULATION OF BEVEL GEAR CUTTING - Simulation based Approach for Tool Wear Analysis . In Proceedings of 1st International Conference on Simulation and Modeling Methodologies, Technologies and Applications - Volume 1: MSIE, (SIMULTECH 2011) ISBN 978-989-8425-78-2, pages 513-520. DOI: 10.5220/0003648605130520


in Bibtex Style

@conference{msie11,
author={Christian Brecher and Fritz Klocke and Christof Gorgels and Ario Hardjosuwito},
title={MANUFACTURING SIMULATION OF BEVEL GEAR CUTTING - Simulation based Approach for Tool Wear Analysis},
booktitle={Proceedings of 1st International Conference on Simulation and Modeling Methodologies, Technologies and Applications - Volume 1: MSIE, (SIMULTECH 2011)},
year={2011},
pages={513-520},
publisher={SciTePress},
organization={INSTICC},
doi={10.5220/0003648605130520},
isbn={978-989-8425-78-2},
}


in EndNote Style

TY - CONF
JO - Proceedings of 1st International Conference on Simulation and Modeling Methodologies, Technologies and Applications - Volume 1: MSIE, (SIMULTECH 2011)
TI - MANUFACTURING SIMULATION OF BEVEL GEAR CUTTING - Simulation based Approach for Tool Wear Analysis
SN - 978-989-8425-78-2
AU - Brecher C.
AU - Klocke F.
AU - Gorgels C.
AU - Hardjosuwito A.
PY - 2011
SP - 513
EP - 520
DO - 10.5220/0003648605130520