Validation of a Planar Penetration Calculation for Face Hobbing Generating of Bevel Gears

To simulate face hobbing generating of bevel gears, a mathematical description of the process kinematics was developed and used in a planar penetration calculation. With given gear and tool geometry as well as process data, the simulation provides process characteristics, such as the maximum uncut chip thickness or cutting length. The validation of the manufacturing simulation is accomplished in three steps. First, the plausibility of the simulation results is assessed. Subsequently, the simulation is validated by comparing the simulated to a target tooth flank geometry. Finally, the undeformed chip geometry is compared to chips from the actual manufacturing process.