Numerical Simulation And Experimental Study Of Cutting Force In Gear Shaping

Gear shaping is an important process for gear manufacture. The cutting force provides an important basis for processing technology of gear shaping. It is of great significance for gear shaping cutting force to the cutting heat, tool wear and durability, and the quality of the machined surface, design of the machine tool, cutting tools, fixture, optimization of tool geometry parameters, and the adaptive control of cutting process. With the development of computer technology, the finite element method is introduced to the study in the field of machining process, the complexity of the cutting mechanism, many interference factors, a large amount of experiments are always the difficult proble ms, and the application of mechanical modeling simulating cutting process can forecast and analyze various factors in the whole cutting system. Therefore, the comparison of the finite element numerical simulation and experiment has widely become the study method in the cutting field. Cutting is a complex nonlinear process including material, geometry, contact, finite element software ABAQUS can effectively deal with the nonlinear problems. In order to obtain more precise prediction of gear shaper cutting force, the contents and contributions of the thesis are as follows:Firstly, using the quasi static tensile experiment and split Hopkinson pressure bar to obtain the material stress-strain curve. And then get the parameters of Johnson-Cook(J-C) material model through MATLAB nonlinear simulation.Secondly, in order to accurately explore gear shaping cutting force, the cutting force experiment of rack with only one tooth cutting gear was done in the planner because planning can simulate gear shaping.Lastly, by using the parameters of Johnson-Cook(J-C) material model for simulating the cutting force in ABAQUS. Comparing the results of cutting force of finite element simulation and experiment, it confirmed the validity of J-C material model, the finite element model and the cutting force of finite element simulation, and then the influence factors such as the cut's geometric parameters, and the cutting parameters on cutting force of gear shaping were analyzed by simulation in ABAQUS to explore variation of the cutting force.The J-C material model and the finite element model of gear shaping in this paper can be used to predict the real cutting force of gear shaping accurately. It even can predict the cutting force of efficient gear shaping through changing rota ry feed and radial feed.