Papers by Keyword: Form-Milling

Abstract: Combining the machining process simulation on UG NX software and the mathematically analysis, a new solving method for the tooth crest curve equation of spiral bevel gears is proposed in this paper. The steps are as follows:1) Establishing the gear blank cone equation in the original coordinate system; 2) Finding the gear convex and concave profile equations in the new coordinate system; 3) Integrating the original coordinate system and the new one through geometric transformation and then deducing the tooth crest curve equations on both sides. The equations will help calculate the cutter’s position and pose in addendum chamfering process, with the chamfer automation achieved.

Abstract: Rotor steel has been widely used in marine engineering and power industry because of its high yield stress and anti-fatigue performance at high temperature. The surface integrity must be guaranteed due to severe working environment. Hence it is worth studying residual stress (RS) for its significant influence on the quality of machined part. In this paper, an effective model is built with the help of finite element method (FEM) to evaluate RS induced by machining of rotor steel 26NiCrMoV145. An adaptive mesh control is introduced in this work to avoid excessive element distortion. Johnson-Cook flow stress model is proposed to model workpiece material. Rolling process is necessary to obtain desired RS according to the performance of form-milling process. In order to validate FEM predictions, both milling and rolling experiments have been carried out. The predicted RS profiles are in reasonable agreement with the experimental ones.