The scraping movement of cylindrical gear is realized by superposition of cutting force

CWE calculation is the most computationally intensive task in simulation. Therefore, in order to improve the simulation efficiency, this paper proposes to model only part of the workpiece, and estimate the cutting force of the whole process by superimposing the force required to cut a backlash.

Some of the artifacts used to reduce CWE calculation time are shown in Figure 1.

(a)Uncut workpiece (b)Cutting workpiece

The method of reconstructing Y-axis cutting force through partial workpiece simulation is shown in Figure 2

(a)Single backlash data from workpiece simulation
(b)Sample to sample linear mapping for approximating transient forces
(c)Curve superposition of all gear clearances

In Fig. 2 (a), the CWE and force curve prediction calculation of cutting the backlash are in multiple rotation cycles TG = 60 / (2 π) ω G) completed in spaced blade travel.

In Fig. 2 (b), due to the gradually changing meshing conditions, this paper uses the sample to sample linear mapping between continuous force curves to capture the transient effects affecting the cutting force.

Fig. 2 (b) corresponds to the zoom window in Fig. 7 (a), covering the rotation cycle of a single gear. This mapping is used to correctly scale and adjust the desired force from the remaining ng-1 backlash machining, and the passing period of the blade TP = 60 / (2 π) ω cNc) ; Finally, the total force in MCS in Fig. 2 (c) is estimated by superimposing each force curve predicted during machining of each tooth clearance.

Because the cutting force is not predicted by the whole workpiece shape, but by using the part workpiece simulation method, the author can effectively shorten the simulation time, which can greatly improve the calculation efficiency.

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