Elastic deflection of cutting tools relative to the workpiece is one of the major factors contributing to dimensional part inaccuracies in machining. This paper examines the effect of tool deflection in gear shaping and its effect on the gear's profile form error, which can cause transmission error and noise during gear operation. To simulate elastic tool deflection in gear shaping, the tool's static stiffness is estimated from impact hammer testing. Then, based on simulated cutter-workpiece engagement and predicted cutting forces, the elastic deflection of the tool is calculated at each time-step. To examine the effect of tool deflection on the profile error of the gear, a virtual gear measurement module is developed and used to predict the involute profile deviations in the virtually machined part. Simulated and measured profile deviations were compared for a one-pass external spur gear process and a two-pass external spur gear process. The simulated profile errors correlate very well with the measured profiles on the left flanks of the workpiece teeth, which are cut by the leading edges of the cutter teeth. However, additional research is needed to improve the prediction of the right flanks, which are cut by the trailing edges of the cutter teeth.
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July 2018
Research-Article
Virtual Model of Gear Shaping—Part II: Elastic Deformations and Virtual Gear Metrology
Andrew Katz,
Andrew Katz
Precision Controls Laboratory,
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
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Kaan Erkorkmaz,
Kaan Erkorkmaz
Precision Controls Laboratory,
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
e-mail: kaane@uwaterloo.ca
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
e-mail: kaane@uwaterloo.ca
Search for other works by this author on:
Fathy Ismail
Fathy Ismail
Precision Controls Laboratory,
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
Search for other works by this author on:
Andrew Katz
Precision Controls Laboratory,
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
Kaan Erkorkmaz
Precision Controls Laboratory,
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
e-mail: kaane@uwaterloo.ca
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
e-mail: kaane@uwaterloo.ca
Fathy Ismail
Precision Controls Laboratory,
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
Department of Mechanical and
Mechatronics Engineering,
University of Waterloo,
Waterloo, ON N2 L 3G1, Canada
1Corresponding author.
Part I of this paper can be found at: http://manufacturingscience.asmedigitalcollection.asme.org/article.aspx?articleid=2676044
Manuscript received July 28, 2017; final manuscript received March 5, 2018; published online April 16, 2018. Assoc. Editor: Laine Mears.
J. Manuf. Sci. Eng. Jul 2018, 140(7): 071008 (10 pages)
Published Online: April 16, 2018
Article history
Received:
July 28, 2017
Revised:
March 5, 2018
Citation
Katz, A., Erkorkmaz, K., and Ismail, F. (April 16, 2018). "Virtual Model of Gear Shaping—Part II: Elastic Deformations and Virtual Gear Metrology." ASME. J. Manuf. Sci. Eng. July 2018; 140(7): 071008. https://doi.org/10.1115/1.4039651
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