Form Error Prediction of Gearcases’ Face Milling

Reducing process development time and costs of new parts implies an increasing need of reliable process simulation. In order to guarantee efficiency to machining simulations, Renault has chosen four criteria that must be respected by such numerical methods: Accuracy, Computation time, Robustness and Easy use. A new numerical method adapted for gearcase milling is presented in this paper. This method is based on the modal behaviour of the workpiece and the tool to provide a form error prediction. This paper uses an illustrative gearcase milling operation to present the method. Predicted results and production reality are showing a good agreement.