Machining Setting Optimization for Formateآ® Face Hobbing of Bevel Gears With the Cutting Force and Tool Wear Constraints

Abstract

Trial and error experiments are the dominant approaches to select machining settings and also cutting system design in facehobbing of bevel gears. These timeconsuming experimental tests impose undesired costs to industries. In the present paper, an integrated method is proposed to find optimum machining settings in facehobbing based on minimum machining time and allowable cutting force and tool wear. Cutting blades in facehobbing are converted to many infinitesimal oblique elements along the cutting edge, and the cutting forces and the tool wear are predicted on all these small elements. The constructed optimization problem seeks a facehobbing scenario with minimum plunge time which meets the cutting force or crater wear depth constraints. The proposed method is applied in two case studies successfully to show the capability of the approach.