The Process Parameters Optimization Model of Gear High-speed Dry Hobbing and Its Application System Development

doi:10.3901/JME.2017.01.190

Abstract

Abstract: Gear hobbing process is the most widely used forming process of gear teeth. The development of high-speed dry cutting technology provides a solution for realizing green, efficient and automated gear production. Since the lack of cutting oil in high-speed dry hobbing, the thermal deformation errors of machine tool, the hob life and the quality of workpiece are sensitive to the process parameters, especially the cutting speed and the maximum chip thickness. A hobbing parameter optimization model with hobbing efficiency and cost of single gear as objectives is established, in which the workpiece material, coating of hob, cutting speed, feed rate and maximum chip thickness are considered as variables. With simulation and experiments, the relationships between the tensile strength of materials and the recommended value of cutting speed and the maximum chip thickness respectively in high-speed dry gear hobbing process are established. For the application in automated production line, an online adaptive model for hobbing parameters optimization is proposed, and an application system is also developed based on SINUMERIK 840D system. The application in a gear automated production line for automobile gear box has shown the model and the system is practical.

Key words: parameters optimization, system development, target cost, high-speed dry hobbing

CHEN Peng, CAO Huajun, ZHANG Ying, ZHU Libin, YANG Yong. The Process Parameters Optimization Model of Gear High-speed Dry Hobbing and Its Application System Development[J]. Journal of Mechanical Engineering, 2017, 53(1): 190-197.

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