Prediction and simulation of cutting force in hypoid gear machining using forming method

Cutting force is an important factor which affects the tool wear and machining performance. On the basis of the chip deformation during processing hypoid gears by forming method, a new approach is proposed to calculate the cutting force produced at least by one cutting blade in this paper. Firstly, according to the established forming processing model, the projecting curve of the tooth line on the face cone is fitted, the cutting tool tip point height in the coordinate system is calculated, and the formulas to calculate the cutting area are developed. Afterwards, based on the kinematic and position relationship between the cutting tool and workpiece, the model of the multitooth dynamic cutting force is set up by taking advantage of the oblique cutting theory. On this basis, the program to calculate the cutting force is finished, the simulation is carried out, and the experiment is conducted. The comparison among the results shows that the trend of the cutting forces in three directions is consistent and the error of the forces is small. Therefore, the accuracy of the multitooth dynamic cutting force mode is verified.