On universal milling machines, bevel gears can be produced with standard end mills. Due to the flexible process kinematics, there are fewer restrictions with regard to implementable component geometries compared to conventional gear-cutting processes. The quality requirements for bevel gears allow deviations of only a few micrometers. For this reason, small production-related deviations can lead to the exceedance of the permissible tolerances. Furthermore, surface integrity is decisive for the load-carrying capacity of gears. In this report, the influence of the process on the bevel gear quality and the properties of the near surface zone is analyzed.
Teixeira AlvesJGuingandMde VaujanyJ-P. Designing and manufacturing spiral bevel gears using 5-axis computer numerical control (CNC) milling machines. J Mech Des2013; 135: 024502-1–024502-6.
2.
ÁlvarezALópez de LacalleLOlaizA, et al.Large spiral bevel gears on universal 5-axis milling machines: a complete process. Proc Eng2015; 132: 397–404.
3.
Bieker R. Herausforderungen beim 5-Achsfräsen von Kegelrädern. In: Klocke F and Brecher C (eds) Innovations in bevel gear technology, Aachen, Germany, 12–13 March 2014. Aachen: Apprimus.
4.
JasterM. Multifunctional advancements. The latest in big gear machining with DMG/Mori Seiki. Gear Technol2012; 1: 42–44.
5.
ÁlvarezACallejaAOrtegaN, et al.Five-axis milling of large spiral bevel gears: toolpath definition, finishing, and shape errors. Metals2018; 5: 353–353.
6.
Kubo A and Ueda A. Gear geometry as a function of the production method. Proposal of invo-planar bevel gears for good productivity with 5×-machine. In: Goldfarb V, Trubachev E and Barmina N (eds) Advanced gear engineering. Mechanisms and machine science. Cham: Springer, 2017.
7.
Liu W. Einfluss verschiedener Fertigungsverfahren auf die Graufleckentragfähigkeit von Zahnradgetrieben. PhD Thesis, TU München, 2004.
8.
Staudt J. Funktionsgerechte Bearbeitung von Verzahnungen durch Freiformfräsen. PhD Thesis, RWTH Aachen University, 2016.
9.
CallejaABoPGonzálezH, et al.Highly accurate 5-axis flank CNC machining with conical tools. Int J Adv Manuf Technol2018; 97: 1605–1615.
HabibiMArezooBNojedehMV. Tool deflection and geometrical error compensation by tool path modification. Int J Mach Tools Manuf2011; 6: 440–449.
12.
TsutsumiMToneSKatoN, et al.Enhancement of geometric accuracy of five-axis machining centers based on identification and compensation of geometric deviations. Int J Mach Tools Manuf2013; 68: 11–20.
13.
WinkelmannLEl SaeedOBellM. The capacity of superfinished vehicle components to increase fuel economy, part I. Gear Technol2009; 1: 50–60.
14.
Mikoleizig G. Surface roughness measurements of cylindrical gears and bevel gears on gear inspection machines. In: Proceedings of 2014 fall technical meeting, Arlington, 12–14 October 2014. Alexandria: AGMA.
15.
WojciechowskiSTwardowskiPWieczorowskiM. Surface texture analysis after ball end milling with various surface inclination of hardened steel. Metrol Meas Syst2014; 1: 145–156.
16.
JawahirIBrinksmeierEM’SaoubiR, et al.Surface integrity in material removal processes: recent advances. CIRP Ann Manuf Technol2011; 60: 603–626.
