Optimal calculation and experimental study on cutting force of hypoid gear processed by generating method

The cutting area and cutting force are important factors that affect the tool life and the machining performance of the machine tool. According to the characteristics and actual working conditions of hypoid gear processed by generating method, a new method for calculating the tangential milling force of multi-cutter teeth is presented. The changing rule of cutting area of the tooth surface is analyzed, the boundaries of the cutting area, such as the meshing line, the intersection line between the tool tip and the face cone of the wheel blank, the intersection line between the tool tip and the end face of wheel blank, are calculated, and the formula for calculating the cutting area is derived. According to the relationship of the motion and position between the cutting tool and workpiece, the dynamic tangential cutting force is calculated. The calculation of constant cutting force is completed based on the optimization of feed velocity, and an example is introduced to calculate the cutting area and cutting force. The experiment of variable tangential cutting force and constant tangential cutting force is completed, and the accuracy of the dynamic cutting force model is verified.