Optimization of Cutting/Tool Parameters for Dry High-Speed Spiral Bevel and Hypoid Gear Cutting with Cutting Simulation Experiment

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Abstract
Tool life and the rationality of cutting parameter setting are evaluated directly by cutting force. In order to predict cutting force, and then to optimize the tooth cutting condition for dry high-speed spiral bevel and hypoid gear cutting, this study has established a 2D cutting FEM simulation platform by using DEFORM-2D based on the 2D orthogonal slot milling experiment. Through the platform, using the method of combining single-factor experiment and multi-factor orthogonal experiment, this study has explored the influence of cutting/tool parameters on cutting force in the dry high-speed cutting process of 20CrMnTi spiral bevel and hypoid gear (face hobbing dry cutting process). The results show that from high degree to low degree, the influence of each parameter on cutting force is as follows: feed > cutting speed > relief angle(P.A.side) >blade rake angle, and the influence of the first three parameters is significant, the influence of blade rake angle is not significant; the optimized condition for dry high-speed spiral bevel and hypoid gear cutting is suggested to be: the cutting speed is 300 m/mim, the feed is 0.06 mm/r, the blade rake angle is 14° and the relief angle(P.A.side) is 10°; the cutting edge can be honed moderately, but the hone radius is not bigger than 0.1 mm.

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