Study on process parameter optimization of high-speed dry hobbing considering vibration characteristics

ObjectiveHigh-speed dry hobbing is an efficient and cleaner gear manufacturing technology. It is paramount to solve the serious vibration problem raised in the high-speed dry hobbing process under the high-frequent alternating cutting load, which is beneficial for improving productivity and machining accuracy.MethodsTo this end, an orthogonal test was performed to analyze the influence of process parameters on the hobbing vibration characteristics. Furthermore, a comprehensive indicator for evaluating the hobbing vibration was proposed, and the relation between this indicator and the spindle speed and the axial feed rate was developed. Based on this, a process parameter optimization model was constructed and oriented by the optimal vibration indicator and shortest cutting time.ResultsCompared to the original cutting conditions, the optimized cutting parameters enable the reductions of cutting time by 26% and vibration comprehensive indicator by 23%. Moreover, the dimensional accuracy of the machined gears can also be improved. The results can provide an important basis for the optimal selection of process parameters achieving the high-efficiency and high-stability high-speed dry hobbing.