The dual interlocking circular cutter (DICC) cutting method, used to produce straight bevel gears (SBGs), employs two interlocked cutters to generate tooth surfaces with a combination of profile and lengthwise crowning. The gear pairs produced have the advantage of low assembly sensibility. However, the cutting method can only be carried out on a dedicated machine with complicated mechanisms, which are not only difficult to setup but also reduce stiffness and accuracy. Gleason recently applied this cutting method on the modern CNC bevel gear-cutting machine to increase productivity and accuracy in manufacturing SBGs; however, they revealed no details of this application because of commercial considerations. The main goal of this work, therefore, is to establish a mathematical model of an SBG produced by the DICC method on a virtual machine. The work gear is cut by an imaginary generating gear that enables derivation of the SBG tooth surface. Ease-off and tooth contact analysis (TCA) are applied to confirm the correctness of the proposed model. A cutting method is also proposed that can be transformed from a specific traditional machine to a modern CNC bevel gear-cutting machine. Conversion from the virtual machine enables derivation of the five-axis nonlinear machine coordinates and subsequent programming of the NC data. Finally, the correctness of NC data for machining is confirmed using the vericut nc verification software.
Straight Bevel Gear Generation Using the Dual Interlocking Circular Cutter Cutting Method on a Computer Numerical Control Bevel Gear-Cutting Machine
National Taiwan University of
Science and Technology,
No. 43, Sec. 4, Keelung Road,
Taipei 106, Taiwan
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received December 26, 2014; final manuscript received June 12, 2015; published online September 9, 2015. Assoc. Editor: Guillaume Fromentin.
Shih, Y., and Hsieh, H. (September 9, 2015). "Straight Bevel Gear Generation Using the Dual Interlocking Circular Cutter Cutting Method on a Computer Numerical Control Bevel Gear-Cutting Machine." ASME. J. Manuf. Sci. Eng. February 2016; 138(2): 021007. https://doi.org/10.1115/1.4030937
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