Tool wear in the gear hobbing process while regarding the working angles

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One of the most productive methods for manufacturing external cylindrical gears is gear hobbing. For serialproduction of large module gears with mn > 6 mm, increasingly tools based on indexable carbide inserts areapplied. In comparison to conventional hobs, these tools divide the tool profile onto multiple cutting edges.Furthermore, it is possible to vary the clearance and rake angle in a significantly wider range by usingindexable inserts rather than conventional hobs. Despite the broad industrial use of indexable insert hobs, thetool life is not yet predictable due to unexpected wear development. In order to overcome these limitations, thestill unknown influences of the cutting edge angles on the tool wear have to be examined.The objective of this research project is a tool wear model for indexable insert hobs. Therefore, a method forcalculating characteristic values for the hobbing process based on a mathematical model is to be developed.Based on these values, the wear model describes the main tool wear of indexable insert hobs. Besides thismathematical model, the influence of the tool rake and clearance angle will be measured in analogy trials. Bycomparing the results of the trials with the characteristic values, the wear model will be trained and improved.Finally, the wear model will be validated through a hobbing trial.