Cutting forces in gear machining by disk milling cutters

• Main Authors: S. Pasternak, Y. Danylchenko
• Format: Article
• Language: English
• Published: Igor Sikorsky Kyiv Polytechnic Institute 2018-05-01
• Series: Mechanics and Advanced Technologies
• Subjects: cutting force; disc-shaped milling tool; gear cutting
• Online Access: http://journal.mmi.kpi.ua/article/view/118609

Purpose. Experimental study of cutting force components when gear cutting with disc-shaped milling tools by using different machining strategies as well as determination of advantages and disadvantages of these strategies based on obtained experimental results. Design/methodology/approach. This paper is dedicated to the experimental study of cutting force components and their variation when gear cutting with disc-shaped milling tools by using different machining strategies as well as to the subsequent discussion of obtained experimental results. Findings. It was found that the known strategies for material removal, tool movement (its running-in or running-out) and tool engagement when gear cutting with disc-shaped milling tools have different force characteristics. This can lead to the different roughness and surface quality of the tooth flanks as well as to different tool wear rates and manufacturing costs. Thus, the consideration of the radial, axial and tangential forces is very important for a correct selection of an optimal machining strategy and optimal cutting parameters for each manufacturing task. Originality/value. The experimental results show that the known strategies for gear cutting with disc-shaped milling tools have different force characteristics. This can influence machining quality and tool wear rate as well as lead to increase in manufacturing costs. It means that, in order to select a perfectly suitable machining method with the optimal process parameters for each individual manufacturing task and thereby to increase the efficiency of the gear manufacturing, the profound knowledge about achievable quality parameters and tool life are required.