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Abstract

Based on comprehensive interrelated mathematical and graphical-analytical models, including 3D cut layers and simulation of contact, strain, force, and thermal processes during gear hobbing friction forces, heat fluxes, and temperature on the teeth of the hob surface are investigated. Various physical phenomena are responsible for their wear: friction on contact surfaces and thermal flow. These factors act independently of each other; therefore, the worn areas are localized in different active parts of the hob. Friction causes abrasive wear and heat fluxes result in heat softening of the tool. Intense heat fluxes due to significant friction, acting on areas of limited area, lead to temperatures exceeding the critical temperature on certain edges of the high-speed cutter. Simulation results enable identification of high-temperature areas on the working surface of cutting edges, where wear is caused by various reasons, and make it possible to select different methods of hardening these surfaces. To create protective coatings with maximum heat resistance, it is advisable to use laser technologies, electro spark alloying, or plasma spraying, and for coatings that provide reduction of friction on the surfaces – formation of diamond-containing layers with minimum adhesion properties and low friction coefficient on the corresponding surfaces.
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Bibliography

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2. V. Dimitriou, N. Vidakis, and A Antoniadis. Advanced computer aided design simulation of gear hobbing by means of three-dimensional kinematics modeling. Journal of Manufacturing Science and Engineering, 129(5):911–918, 2007. doi: 10.1115/1.2738947.
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4. I. Hrytsay, V. Stupnytskyy, and V. Topchii. Improved method of gear hobbing computer aided simulation. Archive of Mechanical Engineering, 66(4):475–494, 2019. doi: 10.24425/ame.2019.131358.
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12. K.-D. Bouzakis, E. Lili, N. Michailidis, and O. Friderikos. Manufacturing of cylindrical gears by generating cutting processes: A critical synthesis of analysis methods. CIRP Annals, 57(2):676–696, 2008. doi: 10.1016/j.cirp.2008.09.001.
13. B. Karpuschewski, H.J. Knoche, M. Hipke, and M. Beutner. High performance gear hobbing with powder-metallurgical high-speed-steel. Procedia CIRP, 1:196–201, 2012. doi: 10.1016/j.procir.2012.04.034.
14. B. Karpuschewski, M. Beutner, M. Köchig, and C. Härtling. Influence of the tool profile on the wear behaviour in gear hobbing. CIRP Journal of Manufacturing Science and Technology, 18:128–134, 2018. doi: 10.1016/j.cirpj.2016.11.002.
15. F. Klocke, C. Gorgels, R. Schalaster, and A. Stuckenberg. An innovative way of designing gear hobbing processes. Gear Technology, 1:48–53, 2012.
16. C. Claudin, and J. Rech. Effects of the edge preparation on the tool life in gear hobbing. In Proceedings of the 3rd International Conference on Manufacturing Engineering (ICMEN), pages 57–70, Chalkidiki, Greece, 1–3 October 2008.
17. J. Rech. Influence of cutting edge preparation on the wear resistance in high speed dry gear hobbing. Wear, 261(5-6):505–512, 2006. doi: 10.1016/j.wear.2005.12.007.
18. C. Claudin, and J. Rech. Development of a new rapid characterization method of hob’s wear resistance in gear manufacturing – Application to the evaluation of various cutting edge preparations in high speed dry gear hobbing. Journal of Materials Processing Technology, 209(11):5152–5160, 2009. doi: 10.1016/j.jmatprotec.2009.02.014.
19. B. Hoffmeister. About Wear on the Hob. D.Sc. Thesis, RWTH Aachen, Germany, 1970 (in German).
20. I. Hrytsay, and V. Stupnytskyy. Prediction the durability of hobs based on contact, and friction analysis on the faces for cutting teeth, and edges during hobbing. In: V. Ivanov, J. Trojanowska, I. Pavlenko, J. Zajac, D. Peraković (eds): Advances in Design, Simulation and Manufacturing IV. Lecture Notes in Mechanical Engineering. Springer, 1:405–414, 2021. doi: 10.1007/978-3-030-77719-7_40.
21. F. Klocke. Manufacturing Processes, Cutting. Springer, RWTH edition, 2011.
22. M.P. Mazur, V.M. Vnukov, V.L. Dobroskok, V.O. Zaloga, J.K. Novosiolov, and F.J. Yakubov. Fundamentals of the Theory of Cutting Materials. Novyy Svit, 2011 (in Ukrainian).
23. I. Hrytsay, V. Stupnytskyy, and V. Topchii. Simulation of loading, and wear rate distribution on cutting edges during gears hobbing. Archive of Mechanical Engineering, 68(1):52–76, 2021. doi: 10.24425/ame.2021.137041.
24. A.B. Aleksandrovich, B.D. Danilenko, Y.V. Loshchinin, T.A. Kolyadina, and I.M. Khatsinskaya. Thermophysical properties of low-alloy high-speed steels. Metal Science and Heat Treatment, 30:502–504, 1988. doi: 10.1007/BF00777438.
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Authors and Affiliations

Ihor Hrytsay
1
ORCID: ORCID
Vadym Stupnytskyy
1
ORCID: ORCID

  1. Lviv Polytechnic National University, Lviv, Ukraine
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Abstract

The article describes how different friction coefficients under certain cutting conditions and parameters affect the formation of the stress-strain and thermal states of the product when titanium alloy machining. A new research methodology is used for the study. Firstly, in the initial data for simulation, each time a different declared coefficient of friction is proposed, and every such task of the cutting process modelling is solved for various cutting parameters. The second stage analyzes how these coefficients influence the stress-strain and thermodynamic state of the workpiece and tool during cutting, as well as the tool wear dynamics. In the third stage of the study, ways for ensuring these analytically-grounded tribological cutting conditions are proposed. The analysis of different wear criteria in the simulation models of titanium alloys cutting is carried out. Experimental studies confirm simulation results.
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Bibliography

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[40] V. Stupnytskyy and I. Hrytsay. Computer-aided conception for planning and researching of the functional-oriented manufacturing process. In: Tonkonogyi V. et al. (eds): Advanced Manufacturing Processes. InterPartner 2019. Lecture Notes in Mechanical Engineering, pages 309–320. Springer, Cham, 2020. doi: 10.1007/978-3-030-40724-7_32.
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Authors and Affiliations

Vadym Stupnytskyy
1
ORCID: ORCID
Xianning She
1
ORCID: ORCID

  1. Lviv Polytechnic National University, Lviv, Ukraine
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Abstract

Results of complex mathematical and computer simulation of gear hobbing are given. A systematic approach to research allowed for the development of simulation models and sequencing of all aspects of this complex process. Based on the modeling of non-deformable chips, a new analytical method for analyzing hobbing has been proposed. The shear, friction and cutting forces at the level of certain teeth and edges in the active space of the cutter are analyzed depending on the cut thickness, cross-sectional area, intensity of plastic deformation and length of contact with the workpiece has been developed. The results of computer simulations made it possible to evaluate the load distribution along the cutting edge and to predict the wear resistance and durability of the hob cutter, as well as to develop measures and recommendations for both the tool design and the technology of hobbing in general. Changing the shape of cutting surface, or the design of the tooth, can facilitate separation of the cutting process between the head and leading and trailing edges. In this way, more efficient hobbing conditions can be achieved and the life of the hob can be extended.
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Bibliography

[1] B. Karpuschewski, H.J. Knoche, M. Hipke, and M. Beutner. High performance gear hobbing with powder-metallurgical high-speed-steel. In Procedia CIRP, 1:196–201, 2012. doi: 10.1016/j.procir.2012.04.034.
[2] B. Karpuschewski, M. Beutner, M. Köchig, and C. Härtling. Influence of the tool profile on the wear behaviour in gear hobbing. CIRP Journal of Manufacturing Science and Technology, 18:128–134, 2018. doi: 10.1016/j.cirpj.2016.11.002.
[3] K.-D. Bouzakis, O. Friderikos, I. Mirisidis, and I. Tsiafis. Geometry and cutting forces in gear hobbing by a FEM-based simulation of the cutting process. In Proceedings of the 8th CIRP International Workshop on Modeling of Machining Operations, 10-11 May, Chemnitz, 2005.
[4] F. Klocke, C. Gorgels, R. Schalaster, and A. Stuckenberg. An innovative way of designing gear hobbing processes. Gear Technology, May:48–53, 2012.
[5] K.D. Bouzakis, S. Kombogiannis, A. Antoniadis, and N. Vidakis. Gear hobbing cutting process simulation and tool wear prediction models. Journal of Manufacturing Science and Engineering, 124(1):42–51, 2002. doi: 10.1115/1.1430236.
[6] K.D. Bouzakis, E. Lili E, N. Michailidis, and O. Friderikos. Manufacturing cylindrical gears by generating cutting processes: a critical synthesis of analysis methods. CIRP Annals, 57(2):676–696, 2008. doi: 10.1016/j.cirp.2008.09.001.
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[8] K.D. Bouzakis, S. Kombogiannis, A. Antoniadis, and N. Vidakis. Modeling of gear hobbing. Cutting simulation, tool wear prediction models and computer supported experimental-analytical determination of the hob life-time. In Proceeding of ASME International Mechanical Engineering Congress and Exposition, volume 1, pages 261–269, Shannon, 14–19 November, 1999.
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[12] J. Rech. Influence of cutting edge preparation on the wear resistance in high speed dry gear hobbing. Wear, 261(5-6):505–512, 2006. doi: 10.1016/j.wear.2005.12.007.
[13] C. Claudin and J. Rech. Development of a new rapid characterization method of hob’s wear resistance in gear manufacturing – Application to the evaluation of various cutting edge preparations in high speed dry gear hobbing. Journal of Materials Processing Technology, 209(11):5152–5160, 2009. doi: 10.1016/j.jmatprotec.2009.02.014.
[14] B. Hoffmeister. Über den Verschleiß am Wälzfräser (About wear on the hob). D.Sc. Thesis, RWTH Aachen, Germany, 1970 (in German).
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[18] V. Stupnytskyy and I. Hrytsay. Computer-aided conception for planning and researching of the functional-oriented manufacturing process. In: Tonkonogyi V. et al. (eds) Advanced Manufacturing Processes. InterPartner-2019. Lecture Notes in Mechanical Engineering, pages 309–320, 2020. doi: 10.1007/978-3-030-40724-7_32.
[19] I. Hrytsay and V. Stupnytskyy. Advanced computerized simulation and analysis of dynamic processes during the gear hobbing. In: Tonkonogyi V. et al. (eds) Advanced Manufacturing Processes. InterPartner-2019. Lecture Notes in Mechanical Engineering, pages 85–97, 2019. doi: 10.1007/978-3-030-40724-7_9.
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Authors and Affiliations

Ihor Hrytsay
1
ORCID: ORCID
Vadym Stupnytskyy
1
ORCID: ORCID
Vladyslav Topchi
1
ORCID: ORCID

  1. Lviv Polytechnic National University, Lviv, Ukraine
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Abstract

Titanium alloys are difficult-to-machine materials due to their complex mechanical and thermophysical properties. An essential factor in ensuring the quality of the machined surface is the analysis and recommendation of vibration processes accompanying cutting. The analytical description of these processes for machining titanium alloys is very complicated due to the complex adiabatic shear phenomena and the specific thermodynamic state of the chip-forming zone. Simulation modeling chip formation rheology in Computer-Aided Forming systems is a practical method for studying these phenomena. However, dynamic research of the cutting process using such techniques is limited because the initial state of the workpiece and tool is a priori assumed to be "rigid", and the damping properties of the fixture and machine elements are not taken into account at all. Therefore, combining the results of analytical modeling of the cutting process dynamics with the results of simulation modeling was the basis for the proposed research methodology. Such symbiosis of different techniques will consider both mechanical and thermodynamic aspects of machining (specific dynamics of cutting forces) and actual conditions of stiffness and damping properties of the “Machine-Fixture-Tool-Workpiece” system.
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Bibliography

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[9] V. Stupnytskyy and I. Hrytsay. Comprehensive analysis of the product’s operational properties formation considering machining technology. Archive of Mechanical Engineering, 67(2):149–167, 2020. doi: 10.24425/ame.2020.131688.
[10] V. Stupnytskyy, I. Hrytsay, and Xianning She. Finite element analysis of thermal and stress-strain state during titanium alloys machining. In: Advanced Manufacturing Processes II. Lecture Notes in Mechanical Engineering, 629–639, Springer, 2021. doi: 10.1007/978-3-030-68014-5_61.
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Authors and Affiliations

Vadym Stupnytskyy
1
ORCID: ORCID
She Xianning
1
ORCID: ORCID
Yurii Novitskyi
1
ORCID: ORCID
Yaroslav Novitskyi
1
ORCID: ORCID

  1. Lviv Polytechnic National University, Lviv, Ukraine

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