Analysis Of Cutting Forces And Optimization Of Cutting Parameters During Gear Hobbing Process

The continuous development of manufacturing industry improves people's living standard constantly,and the demand of intelligent products of people's daily life boosts the development of manufacturing industry and the creation of new products in turn.The demand for gear is growing as one of the most basic transmission parts in manufacturing industry.Gear hobbing is one of the widely used efficient processing methods to machine rotary gears.Gear hobbing process is complex interrupted cutting process with multi-cutting-edge,so it is need to seek more effective methods to analyze its cutting mechanism,investigate the influence of hobbing cutting parameters on cutting force,cutting temperature and tool wear.And this will build a foundation for the development of gear hobbing technology,so that the gear hobbing can develop from the traditional method to a more energy-efficient and efficient direction.The complex metal cutting process of hobbing is visualized based on the the SolidWorks software platform and the kinematic relationships between the hob and the workpiece.This will lay foundation for the calculation of hobbing forces and the three-dimensional(3D)models of finite element simulation.The genetic algorithm is adopted to optimize the hobbing parameters,in order to reduce the process cost,raise working efficiency,decrease the waste of resources and maximize the efficiency of enterprises.First,mathematical model of hobbing was established and the geometric shape and size of obtained chip were analyzed.Two-dimensional mathematical model of hobbing and three-dimensional mathematical model of hobbing were established based on the gear hobbing kinematic relationships.The path of hobbing teeth was obtained with MATLAB to analyze the cutting area of every tooth.The KYTool was served as the plug-in to secondary development for SolidWorks in the C+ language.The hobbing process simulation is conducted by the secondary development of SolidWorks.And the chip was obtained to analyze the cutting volume of every tooth and the cutting states of the cutting edges.Dispersed coordinate points on the irregular boundary surface of the chip are extracted by the secondary development of SolidWorks.The accuracy of this was verified.Secondly,two methods are adopted to analyze the cutting force with the 3D models of gear workpiece after cut and undeformed chips,namely,analytical method and finite element simulation method.Analytical method is calculation of hobbing force with the shape of chips by extracting dispersed coordinate points on the irregular boundary surface of the chip.Finite element simulation method is finite element simulation of gear hobbing in ABAQUS with the 3D model of the workpiece.Their results are compared,which will demonstrate the correctness of the cutting force got from calculation.The finite element simulation was used to analyze the influence rule of cutting parameters on cutting forces to provide theoretical basis for the selection of cutting parameters.At last,cutting power and cutting parameters were researched.The hob cutting experiment was designed to measure cutting power,the average cutting power got form experiment and a calculation was compared to prove the validity of the calculation results.The genetic algorithm was used to make multi-objective optimization of hob cutting parameter.So the lowest cost of hob and the shortest processing time was obtained.Geometric simulation and finite element simulation provide the technical support for further master hob cutting mechanism and a new research method to study the high-speed dry gear hobbing.The accurate 3D model for finite element simulation can be obtained more convenient and fast.All of work lay the foundation for achieving 'substitute hobbing for rolling'.