An Accurate and Efficient Approach to Undeformed Chip Geometry in Face Hobbing and Its Application in Cutting Force Prediction

Abstract

Due to complexities of facehobbing of bevel gears, such as the intricate geometry of the cutting system, multiaxis machine tool kinematic chains, and the variant cutting velocity along the cutting edge, deriving the instantaneous undeformed chip geometry, as one of the most important characteristic of material removal, is a challenging process. In the present research, all these complexities have been taken into consideration to obtain an inprocess model and undeformed chip geometry, and predict cutting forces. The instantaneous undeformed chip geometry is obtained using the derived inprocess model. As an application of the proposed methods, cutting forces are predicted during facehobbing by oblique cutting theory using the derived undeformed chip geometry and converting facehobbing into oblique cutting. The proposed methods are applied on two case studies of facehobbing of bevel gears and the chip geometry is derived and the cutting forces are predicted.