Research On The Mechanical Modeling And FEM Simulation Of Bevel Gear In High Speed Dry Cutting

High-speed dry cutting technology has gradually become the main developmenttrends in bevel gear milling processing because of its advantages such as highefficiency, high accuracy, low energy consumption and clean environmentalprotection. In comparison with mature high-speed dry cutting technology abroad,domestic related researches in this field is lagged behind. Further studies are neededto promote domestic dry cutting applications and development, especially in theaspect of dry cutting technology.As an important physical phenomenon in cutting manufacture process, cuttingforce not only determines energy consumption and the process system distortion inthe cutting process, but also shows important association with tool wear and its life,chip formation, processing quality and so on. The crucial characteristic in high-speeddry cutting is relatively smaller cutting force, which has important influences onreducing processing energy consumption, improving machining accuracy, reducingtool wear and so on.On the basis of analyzing the easy abrasion drawback of top edge in traditionalbevel gear double disc cutter when cutting big modulus gear, this paper adopted a newtype of bevel gear disc cutter design. Combined with some theories such as cuttingtemperature theory, metal cutting principle and bevel gear processing theory, shearzone stress, strain, strain rate and other problems under high-speed cutting conditionwere analyzed. With the method of cutting edge differential treatment, the formula ofcutting force and share zone temperature in high-speed dry cutting was deduced.With the special metal cutting software--AdvantEdge FEM, this paper studied cuttingsimulation under the condition of different cutting speed, blade angle and cuttingdepth, focusing on the internal and external straight blade knife and circular bladeknife. By means of theoretical analytic calculation, finite element analysis onAdvantEdge FEM, The cutting force variation of high-speed dry milling tooth alongwith cutting speed, amount of feed and cutting depth was discovered. By comparingthe results of finite element simulation, theoretical analytic results with the existingexperimental data, the correctness of cutting force model was verified. Through theanalysis of theories,simulation and actual data results in cutting experimental, the basic mechnasim in high-speed dry cutting was discussed.The research in this paper provides theoretical support for high-speed dry cuttingtechnology of bevel gear. Also, it provides references for the formulation ofprocessing technology and optimization of cutting parameter in high-speed dry cuttingtechnology.