manufacturing of cylindrical gears by generating cutting processes a critical synthesis of analysis methods文档.doc

Manufacturing of cylindrical gears by generating cutting processes A critical synthesis of analysis methods Manufacturing of cylindrical gears by generating cutting processes: A criticalsynthesis of analysis methodsK.-D. Bouzakis (1)*, E. Lili, N. Michailidis (2), O. FriderikosAristoteles University of Thessaloniki, Greece1. IntroductionGears with involute teeth are among the most importantcomponents of efficient modern transmission techniques, con-forming to relevant pollution and energy conservation legislation.The generation of an involute curve is best described by a tightlystretched thread being rolled up on a basic circle (see Fig. 1). Thefront edge of the thread describes an involute. An involute curveshifted along a helix on a basic cylinder, produces a gear flank.Gears of the same module m, possess the same basic rack(reference profile) [48,49]. Most of the quality gears produced inlarge lots are manufactured utilizing gear generating processes,based on the principle that two involute gears, or a gear and a rackmesh together properly. Therefore, a cutting tool with the shape ofa gear or a rack may be used to cut gear teeth in a gear or a rackblank. The tool geometry in conjunction with appropriate machinetool kinematics lead to the same contact conditions as in thecharacteristic gears? pair cases exhibited in Fig. 2. The demon-strated gears? pairs correspond to the manufacturing processes ofgear planing, shaping, skiving and hobbing, respectively.These softmaterial state pre-machining methods with geometrically definedcutting edges are considered as the most characteristic generatingcutting processes for gear manufacturing [1,69].A thorough knowledge of the gear manufacturing processes isof crucial significance to counteract the constantly improvingrequirements of the globalized market place. Although fewcompanies react to the changing product profile by moving theirmanufacturing facilities, others focus on strengthening their corecompetence in g