Computer aided stress and deflection analysis of Fellows gear-shaping cutter, for Tdifferent cutting process parameters

Achieving maximum efficiency (in terms of quantity of products produced in a stipulated time) with improved accuracy and surface finish through a chatter-free high-speed cutting process are problems of the modern gear cutting industry. Modern techniques employ a generating type of cutter such as Fellowʹs gear-shaping cutter for the production of high -speed noiseless and accurate gears. The literature review indicates that experimental and theoretical methods had been predominantly in use in the design of gear cutting tools as compared to the computer aided methods. In this research the gear-shaping cutter is modelled using three-dimensional ten-node tetrahedral finite elements. The research is carried out at the instant when the gear-shaping cutter plunges on the workpiece and the cutting forces during the generation process become maximum. The maximum three-dimensional displacements and stress values are generated under different cutting conditions. The effects of different cutting process parameters (speed, feed and depth of cut) on the maximum stress and deflection are studied in detail.