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Metals 2018, 8(5), 353; https://doi.org/10.3390/met8050353

Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors

1
Ibarmia, Polígono Industrial Etxesaga, s/n, 20720 Azkoitia, Spain
2
Department of Mechanical Engineering, University of the Basque Country (UPV/EHU), Alameda de Urquijo s/n, 48013 Bilbao, Spain
3
CFAA—University of the Basque Country (UPV/EHU), Parque Tecnológico de Zamudio 202, 48170 Bilbao, Spain
*
Author to whom correspondence should be addressed.
Received: 1 April 2018 / Revised: 9 May 2018 / Accepted: 10 May 2018 / Published: 15 May 2018
(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)
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Abstract

In this paper, a five-axis machining process is analyzed for large spiral-bevel gears, an interesting process for one-of-kind manufacturing. The work is focused on large sized spiral bevel gears manufacturing using universal multitasking machines or five-axis milling centers. Different machining strategies, toolpath patterns, and parameters are tested for both gear roughing and finishing operations. Machining time, tools’ wear, and gear surface are analyzed in order to determine which are the best strategies and parameters for large modulus gear manufacturing on universal machines. The case study results are discussed in the last section, showing the capacity of a universal five-axis milling for this niche. Special attention was paid to the possible affectations of the metal surfaces, since gear durability is very sensitive to thermo-mechanical damage, affected layers, and flank gear surface state. View Full-Text
Keywords: gears; multitasking machine; computer aided manufacturing (CAM) gears; multitasking machine; computer aided manufacturing (CAM)
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Álvarez, Á.; Calleja, A.; Ortega, N.; De Lacalle, L.N.L. Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors. Metals 2018, 8, 353.

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