MODEL-BASED PROCESS ANALYSIS FOR GEAR CUTTING WITH INDEXABLE INSERTS

抄録

Hobbing and form milling processes of gears with indexable inserts are investigated in the current work, by means of model-based process analysis. In the applied model, the approach of penetration calculation is extended for indexable inserts applications. Therefore, the tool profile is split to take into account the individual indexable inserts. With the extended model approach the chip geometry for each indexable insert and therefore local characteristic values of the machining process can be calculated. These values are locally calculated for each point at the cutting edge and for each single chip as well as for the complete process. To validate the model both, maximum chip thickness and chip volume, are compared to the real chip geometry. With a validated model, the model-based process analysis can be used to improve the design of hobbing and form milling processes with indexable inserts and to provide a better understanding of both processes.