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Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools

There are many ways of machining gears; the world’s manufacturers of machine tools have patented many methods that allow for the production of gears in an accurate and efficient way. In general, the patented methods require the use of kinematically complex and expensive CNC machine tools. These tool...

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Autor principal: Gołębski, Rafał
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8838948/
https://www.ncbi.nlm.nih.gov/pubmed/35161022
http://dx.doi.org/10.3390/ma15031077
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author Gołębski, Rafał
author_facet Gołębski, Rafał
author_sort Gołębski, Rafał
collection PubMed
description There are many ways of machining gears; the world’s manufacturers of machine tools have patented many methods that allow for the production of gears in an accurate and efficient way. In general, the patented methods require the use of kinematically complex and expensive CNC machine tools. These tools, moreover, the production of the technology itself, including the machining code, require the use of dedicated software. Therefore, it seems justified to strive for the application of kinematically simple and relatively cheap machines in the machining processes so as to increase the universality and availability of new machining methods. This paper presents a method of machining a spur gear with straight teeth with an involute profile using a basic CNC lathe DMG MORI CLX350V4 equipped with driven tools. On the basis of the presented mathematical model, an algorithm was developed to generate a code that controls the machining of cylindrical gears with an involute profile of straight teeth, with the possibility of modifying the transition profile and the tooth root. The machining was experimental, and the gear was made of aluminium AlSi1MgMn using a solid carbide cylindrical cutter. In conclusion, the presented method was found to be very competitive with commercial methods and is able to provide very high quality gears. The accuracy of the machined profile form deviation in the entire processing did not exceed an average value of 10 μm; while assessing the tooth line, the basis average error was 5 μm. Finally, the gear was assessed as manufactured in accuracy class 6. This machining method guarantees very competitive machining cycle times, and thanks to the use of an uncomplicated CNC lathe and universal tools, it provides great flexibility, at the same time giving the possibility of machining gears with arbitrary profiles.
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spelling pubmed-88389482022-02-13 Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools Gołębski, Rafał Materials (Basel) Article There are many ways of machining gears; the world’s manufacturers of machine tools have patented many methods that allow for the production of gears in an accurate and efficient way. In general, the patented methods require the use of kinematically complex and expensive CNC machine tools. These tools, moreover, the production of the technology itself, including the machining code, require the use of dedicated software. Therefore, it seems justified to strive for the application of kinematically simple and relatively cheap machines in the machining processes so as to increase the universality and availability of new machining methods. This paper presents a method of machining a spur gear with straight teeth with an involute profile using a basic CNC lathe DMG MORI CLX350V4 equipped with driven tools. On the basis of the presented mathematical model, an algorithm was developed to generate a code that controls the machining of cylindrical gears with an involute profile of straight teeth, with the possibility of modifying the transition profile and the tooth root. The machining was experimental, and the gear was made of aluminium AlSi1MgMn using a solid carbide cylindrical cutter. In conclusion, the presented method was found to be very competitive with commercial methods and is able to provide very high quality gears. The accuracy of the machined profile form deviation in the entire processing did not exceed an average value of 10 μm; while assessing the tooth line, the basis average error was 5 μm. Finally, the gear was assessed as manufactured in accuracy class 6. This machining method guarantees very competitive machining cycle times, and thanks to the use of an uncomplicated CNC lathe and universal tools, it provides great flexibility, at the same time giving the possibility of machining gears with arbitrary profiles. MDPI 2022-01-29 /pmc/articles/PMC8838948/ /pubmed/35161022 http://dx.doi.org/10.3390/ma15031077 Text en © 2022 by the author. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Gołębski, Rafał
Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools
title Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools
title_full Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools
title_fullStr Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools
title_full_unstemmed Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools
title_short Experimental Method of Machining Gears with an Involute Profile Using CNC Lathe with Driven Tools
title_sort experimental method of machining gears with an involute profile using cnc lathe with driven tools
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8838948/
https://www.ncbi.nlm.nih.gov/pubmed/35161022
http://dx.doi.org/10.3390/ma15031077
work_keys_str_mv AT gołebskirafał experimentalmethodofmachininggearswithaninvoluteprofileusingcnclathewithdriventools