Analysis on wear patterns and mechanisms of carbide tool for face-hobbing of spiral bevel gear

Spiral bevel gear is widely used in the automotive and aerospace manufacturing industries, and the machining process is complex and the material is difficult to cut. The characteristics of high hardness, strong chemical reactivity and poor heat dissipation make the machinability of 20CrMnTi poor for face-hobbing machining of spiral bevel gear. In the process of cutting, there are some problems such as severe tool wear, poor machining quality and low machining efficiency caused by higher cutting force and higher cutting temperature. Therefore, it is necessary to study and analyze the wear experiment of the cutting tools of spiral bevel gear for face-hobbing deeply. Firstly, under the single factor experimental conditions, the wear patterns of inside blade and outside blade are observed and analyzed at different rotational speeds, and the tool wear conditions are detected and measured analysis. Secondly, the tool wear morphology and element distribution of rake face and flank face of inside blade and outside blade are analyzed by scanning electron microscope and energy spectrometer, and the tool wear mechanism for face-hobbing of spiral bevel gear is discussed in depth. The results demonstrate that chipping and fracture are the main patterns of tool wear; the tool wear mechanism are mainly embodied in adhesive wear, diffusion wear and oxidation wear. The tool wear is mainly distributed on the main cutting edge, top edge and corner radius, and the top edge and corner radius are more seriously worn. The research results can provide an effective basis for exploring the tool wear mechanism and improving the tool life, and provide technical support for the design and development of gear machining tools.