Chip geometry and cutting force prediction in gear hobbing

This paper presents a tri-dexel geometric engine integrated simulation model for the gear hobbing operation. The process kinematics are modeled and validated using CNC signals from a Liebherr LC500 hobbing machine. Workpiece geometry updating and cutter-workpiece engagement (CWE) calculations are efficiently realized in the tri-dexel engine. 3D force contributions at discretized nodes along the hob's cutting edges are computed considering the localized principal cutting directions, and rake and inclination angles. To measure cutting forces, a rotary dynamometer is successfully adapted and used alongside a Kalman filter to compensate for structural dynamics. The predicted forces agree well with their experimental counterparts.