Model for tool wear prediction in face hobbing plunging of bevel gears

This paper deals with tool wear investigations for face hobbing plunging of bevel gears. Initially, the influence of process parameters and tool geometry on tool wear is analyzed both in cutting trials and with the help of the manufacturing simulation BEVELCUT. Subsequently, a tool wear model is presented. Input parameters into the model are tool and workpiece data as well as process parameters and chip characteristics. Through the manufacturing simulation BevelCut, which is based on a planar penetration algorithm, chip characteristics such as the maximum chip thickness hcu,maxare calculated resolved in time and location along the blade's cutting edge. Combined with the local cutting speed, the chip characteristics are used to determine the thrust force, which is required to calculate the elastic workpiece deformation. The model coefficients are calibrated by multi-variable regression analysis using the results of the cutting trials and simulation results. The quality of the regression is determined with the help of equivalence tests. For verification, the process parameters and tool geometry are varied in series production and the tool wear is assessed. Finally, the modeled tool wear is compared to the measured tool wear.