Feeding Rate Optimization And Tool Wear Monitoring Of Spiral Bevel Gears CNC Milling

Spiral bevel gear tooth cutting efficiency and the quality of tooth surface machining are mainly influenced by machining process parameters and the condition of tool wear.Due to the complexity of the tooth cutting movement,the actual parameters of tooth cutting process are selected according to the manual and the state of tool wear during machining is judged empirically.Unreasonable process parameters not only lead to a waste of cutting performance of the tool,but also accelerate the wear of the tool.Current research on the optimization of process parameters and monitoring of tool wear is focused on general milling and cylindrical gear hobbing.Fewer studies have been carried out on the optimization of process parameters and the monitoring of tool wear status in the gear cutting process of spiral bevel gears.This paper addresses this issue by analyzing the relative motion of tooth cutting during tooth milling according to the principle of tooth cutting.Combined with the principle of oblique cutting,a mathematical model for the calculation of cutting forces during tooth surface cutting is established.The formula for calculating the coordinates of the tool position during tooth cutting is derived from the tooth forming principle.A method for solving the cutting area of internal and external tools for cutting teeth is proposed using the Open CASCAD geometric engine and Boolean operations.Using the finite element method,relationships between cutting force and feed rate,cutting force and cutting temperature and cutting force and tool life were established.The theoretical analysis of the improvement of gear milling efficiency,the reduction of peak cutting force and the extension of tool life were carried out respectively,using the cutting force during gear cutting as an intermediate parameter.And relevant validation experiments were carried out.Based on the characteristics of tooth milling and existing tool wear monitoring methods,a tool wear condition monitoring model was established.Tool wear monitoring experiments were carried out using the vibration signal during tooth milling as the monitoring signal.The research in this paper has enabled accurate prediction of the trend of cutting forces during tooth cutting.Based on the predicted cutting force trend,the gear cutting feed rate is optimized.The objectives of improving gear cutting efficiency,reducing peak cutting forces and extending the service life of the gear milling tool are achieved.The research has good engineering application value for optimizing spiral bevel gear machining process parameters and determining tool wear status.