Study on the analytical prediction of premier chipping in the involute gear-cutting process

Abstract In machining processes, tool chipping is known to be most dangerous when the variation of the end of the tool edges is largest. Therefore, chipping has been assessed by the stress distribution at the instant of cutting. In this study, in order to predict the shapes of tool chipping with the tool shapes and the cutting conditions, the premier chipping shapes of an involute cutter are predicted by the stress-distribution value of the cutting edges, and are verified by the results of experiment. The growth behavior of the tool chipping is considered through experiments into gear cutting and from the evaluation of the specific cutting energy under proper machining conditions through simulation results it is known that the accurate prediction of cutting force is possible.