Experimental and numerical determination of cutting forces and temperatures in gear hobbing

Hobbing is one of the most productive methods for manufacturing external gears. According to the requirements of green manufacturing, the lubrication in gear hobbing has to be reduced with the final aim of dry machining. Influences due to thermal aspects during machining have to be considered, especially in hobbing of large modules or ring gears, because in this case, hobbing could be the last step in the process chain. Within the priority program (SPP) Modeling, Simulation and Compensation of Thermal Effects for Complex Machining Processes, founded by the DFG, special emphasis is laid on the thermally caused geometrical deviation in dry cutting. To predict the heat flux, which leads to thermal expansions and geometrical deviations of the gear, a validated model for forces and temperatures is necessary. The validation of single generation positions and chips is focused in this paper.