Cutter Workpiece Engagement Calculations for Milling of Spur Gear with Ball-End Cutters
This paper presents a new solid model for calculating the cutter-workpiece engagement ( CWE) boundaries in the ball-end finish milling process of spur gear. The kinematics model between the milling cutter and gear is first described. Based on the model of spur gear tooth,a new method to generate constant scallop height tool paths for ball-end milling is developed. Updating in-process workpiece is constructed by performing a subtraction boolean operation between the in-process workpiece and tool swept volume mod-el;The CWE is extracted from the updating in-process workpiece based on spherical geometry;The engage-ment angles are calculated by Slicing the CWE surfaces with the parallel planes along tool axis;The confir-mation of the validity and accuracy of the proposed method has been accomplished by the contrast between simulation results and the results from gear milling experiments,expressing a faultless agreement between them . The extraction of the cutter-workpiece engagement provide the whole geometrical information needed for further research,such as prediction of the cutting forces and tool wear development.
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