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Use of Mechatronic System to Manufacture Spiral Bevel Gear using 3-Axis CNC Milling
Machine
S.Mohsen Safavi
S.S. Mirian
M. Karimian Sichani
Assistance professor
Lecturer
MSc. student
Isfahan University of Technology Islamic Azad University of Najafabad Isfahan University of Technology
mosafavi@cc.iut.ac.ir
mirian@cc.iut.ac.ir
mkarimian@me.iut.ac.ir
R. Abedinzade
MSc. student
Isfahan University of Technology
abedinzade@me.iut.ac.ir
Abstract
Gears are crucial components for modern precision
machinery as a means for the power transmission
mechanism. Due to their complexity and unique
characteristics, gears have been designed and
manufactured by a special type of machine tools, such
as gear hobbing and shaping machines. The spiral bevel
gears (SBG) are the most complex type and are used to
transmit the rotational motion between angularly
crossed shafts. In this paper, we attempt to manufacture
the spiral bevel gear by a three-axis CNC milling
machine interfaced with an additional PLC module.
This consists of (a) Geometric modeling of the spiral
bevel gear. (b) Simulating the traditional and our new
non-traditional method using a CAD/CAE system. (c)
Process planning for CNC machining and PLC
programming. Experimental cuts were made to discover
the validity of the presented method with a three-axis
CNC milling machine.
= 35 o
Shaft Angle
No. of Teeth
Spiral direction
Face Width
Pitch Angle
= 90 o
Root Angle
Face Angle of
Blank
Tooth Thickness
Z 1 = 20
Left Hand
Z 2 = 20
Right Hand
b=15
1 = 45
2 = 45
f 1 = 40.802
f 2 = 40.802
k 1 = 49.198
k 2 = 49.198
K=4.4584
f 1 = tan 1 (h f 1 R )
(3)
f 2 = tan
(4)
(h
f2
R)
k1 = 1 + f 2
(5)
k2 = 2 + f1
(6)
f 1 = 1 f1
(7)
f 2 = 21 f 2
(8)
Machining Strategy
The workpiece is wood and the blank material is premachined as a conic (Face Angle of the gear) form by
turning operation. Standard cutter No.5 used in our
experiment is mounted on the machine spindle and the
gear blank is mounted on outward shaft of worm
gearbox. The tool is fed subsequently (around 30
machining sequence to prevent spoiling work) toward
the center of the gear blank to the desired tooth depth.
When one tooth space has been completed, the tool is
withdrawn; the gear blank is indexed using the AC
motor based on explained procedure, and then is
followed by cutting the next tooth space.
Conclusions
In this paper we attempted to manufacture the spiral
bevel gear using a three-axis CNC milling machine
based on form milling method. Basically, form cutting
uses a simple and flexible method of machining of
gears. The equipment and cutters required are relatively
simple and inexpensive, and standard CNC milling
machine is used. Compared to the conventional gear
cutting method in which dedicated machine tools is
required, the presented method can easily be modified
to produce any type and size of SBGs or any other types
of gears. Also it is a multi-deception system which is a
dynamic and constant evolving technology.
References
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