An accurate approach to determine the cutting system for the face milling of hypoid gears

In this research, mathematical model of an accurate cutting system for the face milling of hypoid gear is developed. For the machining of hypoid gear, a conventional cutter system is considered, which contains the groups of inside and outside blades. These blade models are called accurate due to the consideration of rake, hook, relief and pressure angles in the design. Mathematical representation of the tooth cutting edges of the blades is developed. By assembling the blade models in the cutting system and revolving it around the cutter rotation axis, swept surface and profiles of inside and outside blades are generated. Using the local synthesis method, determination of cutting system geometry is performed for the given parameters of the gear. In cutting system parameters, average cutter radius and pressure angles of the tooth cutting edges are the variables in this algorithm, whereas the hook, rake and relief angles are assumed to be given. Sensitivity analysis is performed, to analyse the sensitivity of the cutting surface, with respect the blade’s rake and hook angle. Finally, an application is presented for a standard gear geometry. A cutter system is determined for the gear and it is virtually face milled, and the geometric parameters are validated against the given parameters of the gear.

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