Process Design Optimization for Face Hobbing Plunging of Bevel Gears

The economic efficiency of cutting processes is generally determined by tool wear. Empirical investigations on tool wear in bevel gear cutting, however, are limited to face milling plunging. Hence, the objective of this paper is to examine the influence of the process design on tool wear for an industrial application of face hobbing plunging. For this purpose, first the influence of cutting speed and feed on process characteristics is analyzed with the help of the manufacturing simulation BevelCut. Subsequently, cutting trials using the same process parameter variations are performed and their influence on tool wear and machining time is assessed. Finally, the simulation results are compared to the results of the cutting trials in order to identify correlations between the process characteristics and the tool wear.