Simulation and experimental study of tool wear in high-speed dry gear hobbing

Gear has been widely applied in the automotive and aerospace manufacturing industries. The machining process is complicated, and the material is difficult to cut. High-speed dry gear hobbing has higher cutting efficiency, but there are some problems in the cutting process, such as larger cutting force and higher cutting temperature, which lead to serious tool wear. Therefore, the wear mechanism of high-speed dry gear hobbing is attracting increasing research attention. Firstly, based on the multi-edge intermittent cutting theory of high-speed dry gear hobbing, the undeformed geometry chip is determined to provide theoretical support for predicting cutting force and tool wear. Secondly, the finite element simulation analysis of high-speed dry gear hobbing is carried out to discuss the chip deformation, tool temperature distribution characteristics, cutting force, tool wear state, and the change law of wear variation in the different cutting parameters. Finally, the wear experiment of high-speed dry hob is performed. The wear trend of the rake face and flank face is discussed, and the wear morphology and mechanism of the tool under different cutting parameters are analyzed. The simulation results are compared with the experimental results, and the simulation results of tool wear forms and wear trends are in good agreement with the experimental results. These findings may provide an effective basis for exploring the wear mechanism of the tool, improving tool life, and providing technical support for the design and development of machining tools for gear.