Modelling of Surface Roughness and Tool Wear when Finishing Milling Process of the Circular Bevel Gear
1
Department of Science and Technology, Hanoi University of Industry, Viet Nam
2
Faculty of Mechanical Engineering, Hanoi University of Industry, Viet Nam
Submission date: 2022-10-05
Final revision date: 2023-03-06
Acceptance date: 2023-03-06
Online publication date: 2023-03-07
Publication date: 2023-04-12
Corresponding author
Journal of Machine Engineering 2023;23(1):154-169
KEYWORDS
TOPICS
ABSTRACT
An experimental process to build the models of surface roughness and tool wear in the finish milling of the Gleason circular bevel gears was carried out in this study. The experiments were conducted according to a Box-Behnken matrix. Three cutting parameters were adjusted in each experiment including cutting speed, feed rate, and depth of cut. From the experimental results, the influences of cutting parameters on the surface roughness and tool wear were analyzed in detail. Two models of surface roughness and tool wear were established with high accuracy. The optimal values of the cutting parameters were also determined to simultaneously ensure the minimum values of two output parameters. The further research directions were also suggested at the end of this study.
REFERENCES (46)
1.
THINH H.X., 2021, Study the Effect of Cutting Parameters on Tooth Surface Roughness and Tool Wear During Finishing Cutting Process of Spiral Bevel Gears Using Hard Alloy Cutter, PhD thesis, Hanoi University of Industry.
2.
MARCINIEC A., PACANA J., PISULA J.M., FUDALI P., 2018, Comparative Analysis of Numerical Methods for the Determination of Contact Pattern of Spiral Bevel Gears, Aircraft Engineering and Aerospace Technology, 90/2, 359–367.
3.
STADTFELD H.J., 2013, Gleason Bevel Gear Technology: The Science of Gear Engineering and Modern Manufacturing Methods for Angular Transmissions, Gleason Works, 2014.
5.
KLINGELNBERG J., 2016, Bevel Gear, Fundamentals and Applications, Germany, Springer Vieweg.
7.
DICH T.V., 2006, Gear Manufacturing Technology, Science and Technics Publishing House, Hanoi.
8.
ESCUDER G.G., BO P., GONZALEZ-BARRIO H., CALLEJA-OCHOA A., BARTON M., LOPEZ DE LACALLE N., 2022, 5-Axis Double-Flank CNC Machining of Spiral Bevel Gears via Custom-Shaped Tools—Part II: Physical Validations and Experiments, The International Journal of Advanced Manufacturing Technology, 119, 1647–1658.
9.
MASSETH J., KOLIVAND M., 2007, Lapping and Superfinishing Effects on Surface Finish of Hypoid Gears and Transmission Errors, Proceedings of the ASME 2007 International Design Engineering Technical Conferences & Computers and Information in Engineering Conference, 2007, Las Vegas, USA.
10.
LIU H., 2016 Effect on Spiral Bevel Gear Tooth Profile, 3rd International Conference on Materials Engineering, Manufacturing Technology and Control, 15–18.
11.
PATHAK S., JAIN N.K., PALANI I.A., 2015, On Surface Quality and Wear Resistance of Straight Bevel Gears Finished by Pulsed Electrochemical Honing Process, International journal of Electrochemical Science, 10, 8869–8885.
12.
ALVAREZ A., CALLEJA A., ORTEGA N., DE LACALLE L. N., 2018, Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors, Metals, 8/5, 1–17.
13.
TRANH N.T., 2008, Location Synthesis and Tooth Contact Analysis for Generation of High-Quality Spiral Bevel Gears, The University of Danang - Journal of Science and Technology, 3/26, 92–98.
14.
PISULA J., PLOCICA M., 2014, Methodology of Designing the Geometry of the Bevel Gear Using Numerical Simulation to Generate the Teeth Flank Surfaces, Acta Mechanica et automatic, 8/1, 5–8.
15.
SOBOLEWSKI B., MARCINIEC A., 2013, Method of Spiral Bevel Gear Tooth Contact Analysis Performed in CAD Environment, Aircraft Engineering and Aerospace Technology, International Journal, 85/6, 467–474.
16.
TOAN T.H., 2016, Research on Machining Helical Bevel Gears on CNC Milling Machines, Master thesis, Hanoi University of Science and Technology.
17.
BRECHER, C., LOPENHAUS C., KNECHT P., 2015, Design of Acoustical Optimized Bevel Gears Using Manufacturing Simulation, 48th CIRP Conference on Manufacturing System – CIRP CMS, 902–907.
18.
BOUQUET J., HENSGEN L., KLINK A., JACOBS T., KLOCKE F., LAUWERS B., 2014, Fast Production of Gear Prototypes - a Comparison of Technologies, 6th CIRP International Conference on High Performance Cutting, 77–82.
19.
HE D., DING H., TANG J., 2018, A New Analytical Identification Approach to the Tooth Contact Points Considering Misalignments for Spiral Bevel or Hypoid Gears, Mechanism and Machine Theory, 121, 785–803.
20.
ALVAREZ A., LOPEZ DE LACALLE L N., OLAIZ A., RIVERCO A., 2015, Large Spiral Bevel Gears on Universal 5-Axis Milling Machines: a Complete Process, The Manufacturing Engineering Society International Conference, 397–404.
21.
XIANG S., LI H., DENG M., YANG J., 2018, Geometric Error Analysis and Compensation for Multi-Axis Spiral Bevel Gears Milling Machine, Mechanism and Machine Theory, 121, 59–74.
22.
KHALILOURAZARY S., DADVAND A., AZDAST T., MOHANMAND H.S., 2011, Design and Manufacturing of a Straight Bevel Gear in Hot Precision Forging Process Using Finite Volume Method and CAD/CAE Technology, Springer.
23.
HUR N., PARK M.W., LEE H.W. 2016, Computer Aided Design of Spherical Involute Bevel Gears, International Journal of Applied Engineering Research, 11/23, 11481–11486.
24.
CHANG S.H., JOHN J.C., HUSTION R.L., 1987, Computer Aided Design of Bevel Gear Tooth Surface, the Fifth International Power Transmission and Gearing Conference, Chicago, Illinois.
25.
OZIL C., 2012, A Study on Cutting Errors in the Tooth Profiles of the Spur Gears Manufactured in CNC Milling Machine, The International Journal of Advanced Manufacturing Technology, 59, 243–251.
26.
BATSCH M., 2020, Mathematical Model and Tooth Contact Analysis of Convexo-Concave Helical Bevel Novikov Gear Mesh, Mechanism and Machine Theory, 149, 103842, 1–18.
27.
THINH H.X., DONG P.V., QUOC T.V., 2022, Influence of Cutting Parameters on Surface Roughness of Teeth When Fine Milling of Spiral Bevel Gear, Technology Reports of Kansai University, 62/7, 3401–3409.
28.
THINH H.X., DONG, P.V., QUOC, T.V., KIEN, N.H., 2018, Study on Influence of Cutting Parameters (S,t) on Surface Roughness of Tooth Flank when Machining Gleason-Curved Toothed Teeth Using Carbide-Tipped Tool, Science and Technology Journal, 49, 76–80.
29.
WU M., ZHANG J., MA C., ZHANG Y., CHENG Y., 2021, Experimental Research on the Surface Quality of Milling Contour Bevel Gears, Research Square, 1–24.
30.
ALVAREZ A., CALLEJA A., ARIZMENDI M., GONALEZ H., de LACALLE L.N.L., 2018, Spiral Bevel Gears Face Roughness Prediction Produced by CNC End Milling Centers, Materials, 11/1301, 1–20.
31.
SHAIKH J.H., JAIN N.K., 2014, Modeling of Material Removal Rate and Surface Roughness in Finishing of Bevel Gears by Electrochemical Honing Process, Journal of Materials Processing Technology, 214 200–209.
32.
PATHAK S., JAIN N.K., PALANI I.A., Improving Surface Quality of Bevel Gears by Pulsed – Ech Process, Daaam International Scientific Book, Chapter 19, 2014, 221–238.
33.
THINH H.X., DONG P.V., QUOC T.V., 2020, A Study on the Tool Wear in Milling Process of the Gleason Spiral Bevel Gear, Advances in Science, Technology and Engineering Systems Journal, 5/6, 1402–1407.
34.
KANATNIKOV N., BOBROVSKIJ N., TABAKOV V., ZIBROV P., DRACHEV O., 2018, Simulation of Influence of Cutting Tool’s Construction on Specific Heat Energy in Processing of Bevel Gears, Materials Science and Engineering, 450/032042, 1–6.
35.
PULIKOLLU R.V., BOLANDER N., SHEN T., VIJAYAKAR S., SPIES M.D., 2013, Microstructure-Based Fatigue Life Prediction Tool for Rotorcraft Spiral Bevel Gears, HS International Forum 69, Phoenix, AZ, USA.
36.
LIU J., XIONG J., ZHOU L., GUO Z., WEN H., YOU Q., LI X., LIU J., ZHAO W., 2021, Properties of Tin–Al2o3–Ticn–Tin, Tialn, and Dlc-Coated Ti(C,N)-Based Cermets and Their Wear Behaviors During Dry Cutting of 7075 Aluminum Alloys, Applied Ceramic Technology, 18/3, 792–802.
37.
TRUNG D.D., 2020, Influence of Cutting Parameters on Surface Roughness during Milling AISI 1045 Steel, Tribology in Industry, 42/4, 658–665.
38.
TRUNG D. D., 2021, Influence of Cutting Parameters on Surface Roughness in Grinding of 65G Steel, Tribology in Industry, 43/1, 167–176.
39.
DEAN A., VOSS D., DRAGULJIC D., 2007, Design and Analysis of Experiments – Second Edition, Springer.
40.
DU N.V., BINH N.D., 2011, Design of Experiment Techniques, Science and Technics Publishing House.
41.
GUPTA H.N., GUPTA R.C., MITTA L,A., 2009, Manufacturing Process – Second Edition, New Age International Publishers, New Delhi.
42.
HANDSCHUH R.F., 1995, Thermal Behavior of Spiral Bevel Gears, Army Research Laboratory Technical Report, U.S. Army Research Laboratory Lewis Research Center Cleveland, Ohio.
43.
TRUNG D.D., THINH H.X., 2021, A Multi-Criteria Decision-Making in Turning Process Using the MAIRCA, EAMR, MARCOS and TOPSIS Methods: A Comparative Study, Advances in Production Engineering & Management, 16/4, 443–456.
44.
KESHAVARZ-GHORABAEE M., AMIRI M., ZAVADSKAS E.K., TURSKIS Z., ANTUCHEVICIENE J., 2021, Determination of Objective Weights Using a New Method Based on the Removal Effects of Criteria (MEREC), Symmetry, 13/525, 1–20.
Share
RELATED ARTICLE
| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
We process personal data collected when visiting the website. The function of obtaining information about users and their behavior is carried out by voluntarily entered information in forms and saving cookies in end devices. Data, including cookies, are used to provide services, improve the user experience and to analyze the traffic in accordance with the Privacy policy. Data are also collected and processed by Google Analytics tool (more).
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
