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Abstract

Simulation studies of the hobbing process kinematics can effectively improve the accuracy of the machined gears. The parameters of the cut-off layers constitute the basis for predicting the cutting forces and the workpiece stress-strain state. Usually applied methods for simulation of the hobbing process are based on simplified cutting schemes. Therefore, there are significant differences between the simulated parameters and the real ones. A new method of hobbing process modeling is described in the article. The proposed method is more appropriate, since the algorithm for the momentary transition surfaces formation and computer simulation of the 3D chip cutting sections are based on the results of hobbing cutting processes kinematics and on rheological analysis of the hob cutting process formation. The hobbing process is nonstationary due to the changes in the intensity of plastic strain of the material. The total cutting force is represented as a function of two time-variable parameters, such as the chip’s 3D parameters and the chip thickness ratio depending on the parameters of the machined layer.

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Bibliography

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[4] J. Edgar. Hobs and Gear Hobbing: A Treatise on the Design of Hobs and Investigation into the Conditions Met with Gear Hobbing. Forgotten Books, 2015.
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[7] N. Tapoglou, T. Belis, Taxiarchis, D. Vakondios, and A. Antoniadis. CAD-based simulation of gear hobbing. In Proceeding of 31st International Symposium on Mechanics and Materials, volume 1, pages 41–57, Agia Marina, Greece. 9-14 May, 2010.
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[11] X. Dong, C. Liao, Y.C. Shin, and H.H. Zhang. Machinability improvement of gear hobbing via process simulation and tool wear predictions. The International Journal of Advanced Manufacturing Technology, 86(9-12):2771–2779, 2016. doi: 10.1007/s00170-016-8400-3.
[12] V. Sinkevicius. Simulation of gear hobbing forces. Kaunas University of Technology Journal: Mechanika, 2(28):58–63, 2001.
[13] I. Hrytsay. Simulation of cross-sections, forces and torques during gear machining by hobs. Mashynoznavstvo, 7:19–23, 1998 (In Ukrainian).
[14] I. Hrytsay andV. Sytnik. Force field of screw-type toothing cutter and its quantitative evaluation. Optimization and Technical Control in Engineering and Instrumentation, 371:3–13, 1999 (In Ukrainian).
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[18] N. Sabkhi, A. Moufki, M. Nouari, C. Pelaingre, and C. Barlier. Prediction of the hobbing cutting forces from a thermomechanical modeling of orthogonal cutting operation. J ournal of Manufacturing Processes, 23:1–12, 2016. doi: 10.1016/j.jmapro.2016.05.002.
[19] F. Klocke. Manufacturing Processes 1: Cutting. Springer, 2011.
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Authors and Affiliations

Ihor Hrytsay
1
Vadym Stupnytskyy
1
Vladyslav Topchii
1

  1. Department of Mechanical Engineering Technologies, Institute of Engineering Mechanics and Transport, Lviv Polytechnic National University, Lviv, Ukraine.
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Abstract

The use of elastic bodies within a multibody simulation became more and more important within the last years. To include the elastic bodies, described as a finite element model in multibody simulations, the dimension of the system of ordinary differential equations must be reduced by projection. For this purpose, in this work, the modal reduction method, a component mode synthesis based method and a moment-matching method are used. Due to the always increasing size of the non-reduced systems, the calculation of the projection matrix leads to a large demand of computational resources and cannot be done on usual serial computers with available memory. In this paper, the model reduction software Morembs++ is presented using a parallelization concept based on the message passing interface to satisfy the need of memory and reduce the runtime of the model reduction process. Additionally, the behaviour of the Block-Krylov-Schur eigensolver, implemented in the Anasazi package of the Trilinos project, is analysed with regard to the choice of the size of the Krylov base, the blocksize and the number of blocks. Besides, an iterative solver is considered within the CMS-based method.

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Authors and Affiliations

Thomas Volzer
Peter Eberhard

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