Technlogical Prerequisites for Deformation and Fault of the Cut Layer During the Speed Gear Milling of Hardened Cylindrical Gears on the Basis of the Atomic Approach

Abstract

The scientific foundations of the technological regulation for the selection and assignment of processing parameters during gear milling are based on the fundamental theoretical provisions of the friction theory, mechanical engineering technology and cutting theory. For the first time, the sliding angle was scientifically substantiated during plastic displacement (pre-deformation) of the material, when the material flows around the indenter (tool) without separation from the main mass. Determination of the minimum sliding angles during the processing of large-module gear wheels by milling, based on the physicochemical processes of friction mechanics, can significantly increase the efficiency of the tooth shaping process and the operational properties of their surfaces. An atomic approach to the processes of deformation and destruction of chips during cutting is presented. The resistance to plastic deformation of the cut layer depends on the type of crystal lattice of the processed material, its stacking fault energy, and the presence of impurities at the grain boundaries. The influence of these factors is manifested through the types of dissipative structures that are formed in the process of deformation of the cut layer and determine its localization.

Scientific Basis for the Substantiation of Process Regulations for the Micro-Cutting of Hardened Gears

“…Аs follows from (1), at σs ≤ 2•τ external friction is impossible at any relative embedding; it is also impossible at hi/R = ai/ρ ≥ 0.5 even if the adhesion bond shear strength is zero [1,3,12,16].…”

“…Technological regulation of choice and appointment of parameters of high-speed machining by a blade tool at hobbing, given the maintenance of demanded parameters of a surface layer of gears, establishes optimum conditions of micro cutting when full participation in the removal of the allowance of all gear's teeth of the miller are provided [1,2,3].…”