The Development of Computer Models of Complex Machining Methods in Mechanical Engineering for Systematic Research, Control and Optimization

The results of the development and practical application of a comprehensive system for studying gear cutting processes are presented. The processes are traditional hobbing, modern power skiving, and radial-circular methods. Carrying out these processes is based on the gear teeth continuous generating method using complex kinematics. This complicates the analysis, description and modeling of the processes. The developed system provides for a logical sequence of step-by-step modeling and simulation of interrelated processes and phenomena accompanying gear processing. Reproducing volumetric chips and calculating their parameters provides the basis for determining deformation and contact processes, cutting forces, elastic deformations, machining accuracy and energy costs per operation. After establishing the operation to overcome friction and heat flows, the degree of heating and the temperature of the working surfaces are calculated to predict tool wear and its service life. Based on the parametric non-uniformity of the considered processes, the intensity of oscillations and vibrations of gear cutting machines is predicted, and their impact on the quality of gear surfaces and the accuracy of gears is determined. These approaches enable the study of such processes at the level of individual teeth and blades during cutting. They also allow gear cutting technology and cutting tools to be optimized according to the most important criteria and performance assessments.