摘要：Abstract Bevel and hypoid gears are manufactured by two main processes, face-milling and face-hobbing. In both processes, blade sticks on the cutter head are prone to be worn out at the corner of the cutting edges. Tool wear can cause unpredictable shut down in production line. By controlling and improving the tool wear, the manufacturing efficiency can be increased. A few researches on the tool wear in bevel gear manufacturing processes were done and the only suggested way to improve the tool wear characteristic was to change the gear design which applies limitations in the gear design stage. Large changes in gradients of the working rake and relief angles along the cutting edge are the important geometrical related factor in the tool wear. In this paper, first, full mathematical representation of the blade including the cutting edge and rake and relief surfaces are presented which it cannot be found in literature. Then, a new method is presented to improve the tool wear characteristics by decreasing the gradients of the working rake and relief angles. In order to validate the better tool wear characteristic of the new blade, FEA machining simulations are conducted on both the proposed and conventional blades. The simulations show great improvements in the tool wear characteristics of the new designed blade in comparison with conventional one.
关键词：KeywordsFace-hobbingBevel and Hypoid GearsTool WearRake AngleRelief Angle
