Process optimization of gear grooves processed by end mills

The process optimization of gear grooves processed by end mills can be approached from multiple aspects such as tool selection, path planning, parameter setting, processing strategy, and simulation detection. The following are some key points:

Tool selection and optimization

Tool type: Select the appropriate type of end mill based on the shape and size of the gear groove, such as flat-bottom end mills, ball-end mills, etc. For the processing of precision gear grooves, hard alloy end mills with high precision and good wear resistance can be considered.

Tool coating: Select appropriate tool coatings, such as TiAlN, TiCN, etc., to enhance the hardness and wear resistance of the tool and extend its service life.

Tool geometric parameters: Optimize the tool’s rake Angle, relief Angle, main deflection Angle and other geometric parameters to reduce cutting force and improve cutting efficiency.

Path Planning and Optimization

Equal residual height method: The equal residual height method is adopted to plan the tool path for side milling finishing of the tooth surface to eliminate redundant tool paths and reduce processing time.

Layered milling: For deeper gear grooves, a layered milling method is adopted, with the cutting depth of each layer controlled within a reasonable range to ensure processing accuracy and tool life.

Tool insertion and retraction methods: Optimize the tool insertion and retraction paths to avoid excessive impact and vibration, and improve the quality of the machined surface.

Cutting parameter optimization

Cutting speed: Select an appropriate cutting speed based on the tool material and workpiece material to ensure cutting efficiency and processing quality.

Feed rate: Set the feed rate reasonably to avoid fluctuations in cutting force and surface quality issues during processing caused by excessive or insufficient amounts.

Cutting depth: Select an appropriate cutting depth based on the depth of the gear groove and the rigidity of the tool to ensure processing stability and tool life.

Processing strategy optimization

Separation of rough machining and finish machining: Rough machining is carried out first to remove most of the allowance, and then finish machining is performed to ensure dimensional accuracy and surface quality.

Use of coolant: Coolant is used during the machining process to lower the cutting temperature, reduce tool wear and improve the quality of the machined surface.

Simulation and Detection

Processing simulation: Utilize CAM software for processing simulation to verify the correctness of the CNC processing program and preliminarily verify the efficiency of the tool path.

Online inspection: During the processing, online inspection equipment is used to monitor the processing dimensions and surface quality in real time and adjust the processing parameters promptly.

Post-processing inspection: After the processing is completed, use gear inspection instruments and other equipment to conduct a comprehensive inspection of the gear grooves to ensure that the processing accuracy meets the requirements.