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1
Content available Hob wear prediction based on simulation of friction, heat fluxes, and cutting temperature
Hrytsay Ihor, Stupnytskyy Vadym
Archive of Mechanical Engineering
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2023
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LXX, nr 2
271--286
EN
Based on comprehensive interrelated mathematical and graphical-analytical models, including 3D cut layers and simulation of contact, strain, force, and thermal processes during gear hobbing friction forces, heat fluxes, and temperature on the teeth of the hob surface are investigated. Various physical phenomena are responsible for their wear: friction on contact surfaces and thermal flow. These factors act independently of each other; therefore, the worn areas are localized in different active parts of the hob. Friction causes abrasive wear and heat fluxes result in heat softening of the tool. Intense heat fluxes due to significant friction, acting on areas of limited area, lead to temperatures exceeding the critical temperature on certain edges of the high-speed cutter. Simulation results enable identification of high-temperature areas on the working surface of cutting edges, where wear is caused by various reasons, and make it possible to select different methods of hardening these surfaces. To create protective coatings with maximum heat resistance, it is advisable to use laser technologies, electro spark alloying, or plasma spraying, and for coatings that provide reduction of friction on the surfaces – formation of diamond-containing layers with minimum adhesion properties and low friction coefficient on the corresponding surfaces.
2
Content available Simulation of loading and wear rate distribution on cutting edges during gears hobbing
Hrytsay Ihor, Stupnytskyy Vadym, Topchii Vladyslav
Archive of Mechanical Engineering
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2021
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LXVIII, nr 1
51--76
EN
Results of complex mathematical and computer simulation of gear hobbing are given. A systematic approach to research allowed for the development of simulation models and sequencing of all aspects of this complex process. Based on the modeling of non-deformable chips, a new analytical method for analyzing hobbing has been proposed. The shear, friction and cutting forces at the level of certain teeth and edges in the active space of the cutter are analyzed depending on the cut thickness, cross-sectional area, intensity of plastic deformation and length of contact with the workpiece has been developed. The results of computer simulations made it possible to evaluate the load distribution along the cutting edge and to predict the wear resistance and durability of the hob cutter, as well as to develop measures and recommendations for both the tool design and the technology of hobbing in general. Changing the shape of cutting surface, or the design of the tooth, can facilitate separation of the cutting process between the head and leading and trailing edges. In this way, more efficient hobbing conditions can be achieved and the life of the hob can be extended.
3
Content available Improved method of gear hobbing computer aided simulation
Hrytsay Ihor, Stupnytskyy Vadym, Topchii Vladyslav
Archive of Mechanical Engineering
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2019
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Vol. LXVI, nr 4
475--494
EN
Simulation studies of the hobbing process kinematics can effectively improve the accuracy of the machined gears. The parameters of the cut-off layers constitute the basis for predicting the cutting forces and the workpiece stress-strain state. Usually applied methods for simulation of the hobbing process are based on simplified cutting schemes. Therefore, there are significant differences between the simulated parameters and the real ones. A new method of hobbing process modeling is described in the article. The proposed method is more appropriate, since the algorithm for the momentary transition surfaces formation and computer simulation of the 3D chip cutting sections are based on the results of hobbing cutting processes kinematics and on rheological analysis of the hob cutting process formation. The hobbing process is nonstationary due to the changes in the intensity of plastic strain of the material. The total cutting force is represented as a function of two time-variable parameters, such as the chip’s 3D parameters and the chip thickness ratio depending on the parameters of the machined layer.
4
Content available remote Narzędzia z węglików do szybkościowego nacinania uzębień
Jemielniak K.
Mechanik
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2018
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R. 91, nr 4
292
PL
Koła zębate o modułach mn w zakresie od 1 do 4 mm są szeroko stosowane w samochodowych skrzyniach biegów. W celu uzyskania maksymalnej wydajności koła te obrabia się narzędziami z węglików spiekanych, których potencjał jest nie do końca wykorzystywany ze względu na nieznane ograniczenia procesu i mechanizmy zużycia. Próby trwałości ostrza, przeprowadzone z prędkościami sięgającymi 1000 m/min, pozwoliły na uzupełnienie tej luki informacyjnej.
5
Content available remote Application of Minimal Quantity Lubrication in Gear Hobbing
Stachurski W.
Mechanics and Mechanical Engineering
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2012
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Vol. 16, nr 2
133--140
EN
The results of investigations on application of Minimal Quantity Lubrication (MQL) in gear hobbing are presented in the paper. The experimental stand which allows measurements of cutting forces, Fc, is described. Experiments were carried out for MQL and flood cooling. The influence of the fluid supply methods on tool wear and cutting forces is presented in the paper. The influence of the different workpiece materials is presented, too. The investigations have proved that the using of the MQL method is by all means justified. The results indicate that the hob wear rate is similar for the MQL and for conventional flood cooling. This is also confirmed by the measurements of cutting forces, which values are comparable for both methods.
6
Content available remote Siła skrawania Fc podczas frezowania obwiedniowego kół zębatych z wybranymi metodami chłodzenia i smarowania
Stachurski W., Midera S., Zgórniak P.
Archiwum Technologii Maszyn i Automatyzacji
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2010
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Vol. 30, nr 4
37-46
PL
W artykule oceniono wpływ wybranych warunków obróbki na wartość siły skrawania Fc podczas frezowania obwiedniowego kół zębatych. Ocenę oparto na równaniach w postaci wielomianów potęgowych, otrzymanych na podstawie wyników badań eksperymentalnych. Badania wykonano podczas frezowania stali węglowej C45 z udziałem cieczy obróbkowej podawanej w trybie obfitym, z minimalnym wydatkiem (MQL) oraz podczas podawania schłodzonego sprężonego powietrza bez udziału cieczy obróbkowej. W końcowej części artykułu przeanalizowano uzyskane zależności matematyczne i zweryfikowano je eksperymentalnie.
EN
In the paper evaluation of the influence of selected cutting conditions on cutting forces during hobbing are presented. Evaluation was carried out on the base of polynomial equations obtained during experimental tests. C45 steel gears were manufactured with application of different types of cooling method: wet machining, minimum quantity lubrication (MQL) and cooled compressed air method. Finally, analysis of mathematical equations, obtained on the base of experimental test, was carried out. Also additional experimental test were done to prove correctness of obtained mathematical relationships between forces and others cutting conditions.
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