Kondrashov A.G., Safarov D.T., Faskhutdinov A.I., Kazargeldinov R.R. Technology of Forming of Helical Ring Gears with Disk Cutters and End Mills on Five-Axis CNC Machines

DOI: 10.18503/1995-2732-2023-21-3-123-136

Abstract

Problem Statement (Relevance). The design of modern heavy-duty vehicles includes a very wide range of gears with a non-standard profile. The production of experimental batches of such gears, when applying conventional approaches to the preparation of production, requires much time and financial expenses for ordering, designing and manufacturing a special gear-cutting tool. The development of multi-axis machines with computer numerical control (CNC) provides for such machining with a universal tool. The paper presents a review of methods of machining gears with a disk-type tool, namely cutter heads and disk cutters, when manufacturing gears. It describes disadvantages of the methods under study, when manufacturing prototypes of ring gears. The authors present algorithms for calculating the axes of working strokes of the tool and experimental data on machining of ring gears with transverse and longitudinal working strokes. The paper contains an estimated error of the profile according to the measurement data on a tooth-measuring coordinate measuring machine. Objectives. The research is aimed at reducing the price and periods for preparing production of helical ring gears on small batch and pilot production, while ensuring performance compared with machining with special tooth cutting tools. Methods Applied. The authors applied mathematical methods of matrix transformations. Originality. For the first time, the domestic automotive industry used the technology of forming ring gears with a universal disk cutter due to the capabilities of modern five-axis CNC machines, including machining of evolvement surfaces and the tooth gullet, as well as chamfering along the edges of the teeth. Result. The developed technology of machining is universal, while ensuring high accuracy of machined ring gears compared with accuracy of machining with conventional methods of gear machining, namely with hobbing or gear-shaping cutters. Practical Relevance. The technology has been introduced into pilot production of helical ring gears to reduce the period of preparation for the production of new gears from 2-3 months to 1-2 hours as time is not spent on manufacturing special clamping mandrels and gear-cutting tools.

Keywords

cylindrical helical gear, ring gear, gear-cutting tools, disk cutter, gear milling, CNC machine

For citation

Kondrashov A.G., Safarov D.T., Faskhutdinov A.I., Kazargeldinov R.R. Technology of Forming of Helical Ring Gears with Disk Cutters and End Mills on Five-Axis CNC Machines. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2023, vol. 21, no. 3, pp. 123-136. https://doi.org/10.18503/1995-2732-2023-21-3-123-136

Aleksei G. Kondrashov – PhD (Eng.), Associate Professor, Naberezhnye Chelny Institute (branch) of Kazan (Volga Region) Federal University, Naberezhnye Chelny, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

Damir T. Safarov – PhD (Eng.), Associate Professor, Naberezhnye Chelny Institute (branch) of Kazan (Volga Region) Federal University, Naberezhnye Chelny, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0002-8297-4524

Ayrat I. Faskhutdinov – PhD (Eng.), Associate Professor, Naberezhnye Chelny Institute (branch) of Kazan (Volga Region) Federal University, Naberezhnye Chelny, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

Ramil R. Kazargeldinov – Lead Design Engineer, PJSC KAMAZ, Naberezhnye Chelny, Russia.

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