Modeling of thermal fluxes in the "composite modular hob-chip-gear rim" system during the hobbing of large-module gears
DOI:
https://doi.org/10.31471/1993-9965-2025-2(59)-134-143Keywords:
gear hobbing, assembled worm modular hob, carbide insert with curvilinear rake face, large-module gears, heat flux distribution.Abstract
The temperature distribution on the working surfaces of the cutting edge of the carbide insert is one of the most significant characteristics defining the operating conditions of an assembled worm-type modular gear hob. It has a considerable influence on the wear patterns of these surfaces. The durability of assembled worm modular hobs can be increased not only by improving the heat resistance of the tool material but also by enhancing the heat dissipation conditions. The latter affects the removal of the heat generated during the cutting process at the insert’s cutting edge, which causes its heating to high temperatures. The efficiency of the gear hobbing process can be assessed based on the analysis of the temperature distribution on the contact surfaces of the assembled worm hob. The shape of the rake face of the carbide insert has the greatest impact on tool life during the cutting process. This study focuses on analyzing the distribution of heat fluxes during the hobbing of large-module gear rims of ore-grinding mills made of high-alloy steels using assembled worm modular hobs equipped with mechanically clamped polyhedral carbide inserts having a curvilinear rake face. The regularities of heat flux distribution during gear hobbing and the removal of large chip sections are investigated to gain insight into the physical nature of the cutting process. The influence of the temperature on the rake face of the carbide insert increases with the thickness of the removed chip layer. A mathematical model has been developed to describe the distribution of heat fluxes during the hobbing of large-module gear rims of ore-grinding mills using assembled worm modular hobs with a curvilinear rake face under conditions of large chip removal. The proposed model makes it possible to predict, for given cutting conditions, the distribution of heat fluxes and the temperature within the system comprising the carbide insert of the assembled worm modular hob, the chip, and the gear rim. The heating temperature of the rake face of the carbide insert limits the cutting modes permissible according to the wear resistance of the cutting part of the assembled worm hob.
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