Abstract: Wide use of cutting oil in the hobbing process is the major source of environmental pollution and threat to occupational health in the gear hobbing workshop. In recent years, high-speed dry hobbing process has been developed and applied without cutting oil, which is regarded as green manufacturing process for gears. However, due to the lack of cooling effect of cutting oil, dry hobbing process may lead to more serious thermal deformation of machine tool, and decrease machining accuracy. A machine thermal deformation error modeling method is proposed based on homogeneous coordinate transformation principle. Taking a typical one of high-speed dry hobbing machine tool as an example, a practical thermal deformation error model is established according to the characteristics of the machine structure and the kinematic relations of the components. In the model, equations are derived for the calculation of machine tool thermal deformation errors with the thermal deformation errors of the components. The thermal deformation experiments of high-speed dry hobbing machine are designed and carried out, and the model is verified based on experimental data.

Key words: Error compensation, High-speed dry hobbing, Homogeneous coordinate transformation, Thermal deformation, Flexible body, Flow induced noise, Fluid-Structure Interaction, FW-H equation, Large eddy simulation