Exploratory investigation of chip formation and surface integrity in ultra-high-speed gear hobbing |
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| Affiliation: | 1. Department of Mechanical Engineering, Keio University, Yokohama 223-8522, Japan;2. Nidec Machine Tool Corporation, Ritto, Shiga 520-3080, Japan;1. Key Laboratory of Micro-systems and Micro-structures Manufacturing of Ministry of Education, China, Harbin Institute of Technology, Harbin, Heilongjiang 150001, China;2. Center for Precision Engineering, Harbin Institute of Technology, Harbin, Heilongjiang 150001, China;3. College of Precision Instruments and Optoelectronics Engineering, Tianjin University, Tianjin 300072, China;1. Leibniz Institute for Materials Engineering, Dept. of Manufacturing Technologies, Badgasteiner Str. 1-3, D-28359 Bremen, Germany;2. University of Bremen, MAPEX Center for Materials and Processes, Faculty of Production Engineering, Dept. of Manufacturing Processes, Bremen, Germany;1. Department of Mechanical Engineering, Osaka University, Osaka, Japan;2. M4 Sciences Corporation, Lafayette, IN, USA;3. R&D Material and Technology Development, Seco Tools AB, Fagersta, Sweden;4. Center for Materials Processing and Tribology, Purdue University, West Lafayette, IN, USA |
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| Abstract: | Gear hobbing is widely employed to manufacture automotive gears, where the productivity depends on the cutting speed. Currently, gear hobbing is performed at ～300 m/min using high-speed steel hob cutters. In this study, ultra-high-speed gear hobbing was attempted using a large-diameter cemented carbide hob cutter on a gear grinder. This enabled a cutting speed up to 2450 m/min. Many interesting phenomena were acquired in this speed range. Chips were severely oxidized, whereas the gear surface was not affected. Compressive residual stress was generated at the gear surfaces with low surface roughness and high hardness, while the wear of hob cutter was insignificant. |
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