Simulation-Based Prediction of Sub-Surface Properties in Skive-Hobbing

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In skive hobbing the tooth flank is shaped by several tool engagements, each characterized by individual engagement conditions. Depending on these engagement conditions different thermomechanical loads are applied to the tooth flank. In the same way the resulting subsurface properties of the workpiece differ, e.g. magnitude and direction of residual stress. Finally the fatigue strength of the workpiece is influenced by the local distribution of residual stress. The measurement of process induced residual stress distribution is a complex procedure which, if possible at all, results in time-consuming planning and measurement actions. For this reason this project proposal suggests to model process induced residual stresses with respect to their position on the tooth flank. This is achieved by building up a combined model predicting the residual stress and its distribution on the tooth flank. The model consists of an empirical process model based on reference trials, a simulation of the process-kinematics and a calculation of the geometrical engagement conditions. The model enables a forecast of the residual stress with respect to the chosen process parameters of skive hobbing. In the future the model will be applied to plan and optimize cutting and measurement processes as well as for the development of cutting tools.