Simulation Based Design for Large Module Gear Machining with Indexable Inserts

Production processes for large module gears are characterized by small batch sizes and high workpiece costs. Therefore, the production of scrap parts cannot be accepted. Manufacturing processes are often not pushed to their limits so that the limits themselves are often not clearly known. To use the potentials of modern tool and machine tool concepts, a deeper theoretical understanding of the processes is necessary. This applies especially to modern indexable insert gear cutting tools, which gain importance in these processes.In the past, gear cutting processes for large module gears have seldom been a subject of scientific research. Therefore, the design of these processes is largely based on experience. Especially, for the newer and more complex tool concepts using indexable inserts, a possibility to analyze processes theoretically is a key factor for deeper understanding of the processes and tool concepts.In this paper the two most important processes for green machining of large module gears, gear hobbing and form milling, are analyzed using simulation and machining trials. For the process simulation, major changes to existing process simulation tools for gear machining processes were implemented. For suitable machining trials, model processes were developed for milling and hobbing. These allow an analysis of the wear behavior of the tools based on a reduced number of machined parts. In this paper the bridge between simulation and machining for large module gears will be drawn in terms of chip removal and deformation, wear behavior and tool design features. As final result a first method for a simulation based process design will be given.