Detection and visualization of chatter in gear hobbing based on combination of time and frequency domain analysis

This paper presents a method for the detection and visualization of chatter in gear hobbing based on a combination of time and frequency domain analysis of acceleration data. By analyzing the acceleration data of the workpiece rotation shaft, chatter was identified, and the relationship between the vibration of the workpiece rotation shaft of hobbing machine and profile deviation of machined gears was established. First, a hobbing cutting experiment was made with different cutting parameters; meanwhile, DH5922N dynamic signal test analysis system and DH311E acceleration sensors were used to collect acceleration data during the hobbing process. Then, the relationship between tooth passing frequency and chatter was established by time domain and frequency domain analyses; furthermore, variance and root mean square value of acceleration data were calculated to judge the magnitude of data fluctuation to indirectly reflect the stability of the machining process. Finally, by detecting the tooth profile deviation and analyzing surface topographies of machined gears, the relationship between vibration and gear machining quality was established: low vibrational level leads to better gear machining precision and surface topography. The research result can provide a theoretical basis for the accurate selection of machining parameters and excellent structural design of hobbing machine tools.