Manufacturing of cylindrical gears by generating cutting processes: A critical synthesis of analysis methods

The eternal goal achieving optimum gear manufacturing results in a quick and flexible way can be obtained by efficient machine tools and thorough processes know how. Gear manufacturing is associated with complicated generating kinematics, chip formation and tool wear mechanisms. To capture quantitatively the tool wear progress and the cutting loads, empirical, analytical, numerical as well as FEM-based methods describing the chip geometry and predicting the tool life and cutting forces have been developed. The application of innovative tool materials and coatings, optimized tool geometries and appropriate conduct of reconditioning procedures contribute to the significant reducing of the manufacturing cost.