Gears machining by milling tools
by Fabio Sada 2002

[<< -1]
[Homepage]
[Index]
[Gallery]
[MailBox]
[+1>>]


 

7 Mode 2 : Multi-plane machining with stopped table

 


In this machining mode the milling tool moves along its own plane while other machine axes are stopped, so thet it may be carried out also over whole-teeth, not rough machined gears, and over machines with a good static precision but not a good dynamic one.

 Machining layout in internal position = arrive point in continous milling or innest cut in multi-cut mode (fig.12A) Tool assembly for involute machining both continous and multi-cut mode with minimum distance from table to gear edge (fig.13U) show milling in innest conditions.

In this case I suggest to operate first both cuts on left and right flank, and then increase both X-position and cut depth.


Also in this case extreme positions may be easily calculated according to tip diameter and (for example) active profile starting diameter.

Both these values may be modified according to milling path width and tool angle:

 

[9] Extra radius = path width / 2 * TAN(beta0)

 

In enclosed example this extra is considered only for multi-cut planning.

Optimized planning in multi-cut milling mode from 2 to 8 cuts  by using 1 only milling tool; maximum over-stock is equal (fig.06A) Optimized planning in multi-cut milling mode from 2 to 8 cuts  by using 2 milling tool spaced of normal basic pitch;  maximum over-stock is equal (fig.07A)  Diagram for hand-calculation of cuts planning in multi-cut mode; best results when external gap is balanced around external curvature radius Calculated optimized planning belongs to this diagram (fig.08A)  Diagram of otimized planning in multi-cut mode with proper extra-radius due to helix ; for use of 1 milling tool (fig.09A)  Diagram of otimized planning in multi-cut mode with proper extra-radius due to helix ; for use of 2 milling tool , in case krc < 0,50 ; planning is referred to path of front milling tool; krc = tool distance / delta curvature radius (fig.10A)  Diagram of otimized planning in multi-cut mode with proper extra-radius due to helix ; for use of 2 milling tool , in case krc > 0,50 ; planning is referred to path of rear milling tool; krc = tool distance / delta curvature radius (fig.11A) .


A proper EDP software may be used for planning cutting positions, so to have equal and minimum form error for each integer quantity of cuts.

Single unit cut will be repeated for all teeth and for all axial sections planned.

Since form error depends upon curvature radius, best results will be for gears with a lot of teeth , but in case of further grinding this is not a problem anyway.

In case of spur gears it is better to machine the whole facewidth at one time for each planned position.



[<< -1]
[Homepage]
[Index]
[Gallery]
[MailBox]
[+1>>]