Abstract
Abstract
Achieving maximum efficiency (in terms of the quantity of products produced in a stipulated time) with improved accuracy and surface finish through chatter-free high-speed cutting processes are among the challenges of the current gear cutting industry. Modern techniques usually employ generating type of cutters, such as Fellow's gear-shaping cutter, for the production of high-speed low-noise accurate gears. A literature review has indicated that experimental and theoretical methods had been predominantly used in the design of gear cutting tools, compared with computer-aided methods. In this research a gear-shaping cutter for spur gears is modelled using three-dimensional ten-node tetrahedral finite elements. The stress values on the gear-shaping cutter are calculated at different instants of a cutting stroke, assuming different loading conditions. The analysis of stress distribution due to the varying force distribution on the gear cutter edges, for the same cutting and process parameters during the generation process, is believed to be new to the literature.