Finite Element Analysis Of High-speed Dry Gear Hobbing Process

Traditional gear hobbing process rely on the cooling and lubrication action of cutting fluid, however, the use of cutting fluid will not only pollute the environment that it is harmful to the workshop worker’s health, but also lead to higher production costs. So it is not conform to the development of mechanical manufacturing industry now. High-speed dry gear hobbing process completely eliminate the use of cutting fluid, is a green and efficient gear manufacturing process, but there is a series of technical problems like machine tool vibration, cutting zone heat dissipation, machine tool thermal deformation etc. should be solved when developing a high-speed dry gear hobbing machine. It is important to study the chip formation laws, the change rules of cutting force, the distribution of cutting stress and cutting temperature in different hobbing parameters and hobbing processing environment for establishing of the basic theory of high-speed dry gear hobbing and the optimization of cutting process parameters.The paper is under the support of national "863" project, mainly studying of the high-speed dry gear hobbing process based on finite element method, the specific research work are as follows:First of all, hob tooth cutting edge trajectory of the gear hobbing process is established in Mathematics, and the 3D model of gear hobbing process is set up with CAD software, combined with DEFORM3 D software running environment, a convenient and flexible gear hobbing process model and simulation method is established which can work with different parameters and different hobbing environment.Second, the numerical simulation of high-speed dry gear hobbing material removal process is conducted. By studying the undeformed chip models, the 3D simulation chip models and the actual workshop chip models, the high-speed dry gear hobbing chip formation law is obtained, and the reliability of the simulation experiment is verified from the side. With the simulation results, the causes of hobbing tooth failure are studied.Then, the change laws of cutting force in high-speed dry gear hobbing process are studied. Comparing with cutting stress under different parameters, the main factors influencing the cutting stress are mastered, the interaction between cutting stress and cutting force is studied; The temperature field distribution of the cutting area and the hob tooth are studied, as the chips take away most of the heat and the low heat transfer and high temperature resistant features of the coating, high-speed dry hobbing can be realized; The simulation results are verified by high-speed dry gear hobbing temperature thermal imaging experiment; The simulation results of high-speed dry gear hobbing temperature field are effective supports for “the high-speed dry gear hobbing heat transfer model and the temperature field control technology framework”.Finally, hobbing process simulations under different cutting parameters are cunducted and how the cutting parameters affect the performance of high-speed dry gear hobbing are found out. Then, a high-speed dry gear hobbing process parameters optimization method based on FEM is established.