Research on Cutting Force and Its Influence on the Failure Process of Cutting Gears Using the Radial-circular Method

Problem Statement and Purpose of the Work. This article studies the cutting force in the radial-circular method and its influence on the reliability of the gear-cutting process. Relevance. Gear manufacturing machines are classified as automated equipment. This applies to machines equipped with CNC systems, as well as convential machines operating in automatic mode for extended periods, given the high labour intensity of gear cutting operations. It is therefore important to ensure the reliable operation of this type of equipment, since failure in unmanned production conditions can result in significant production losses. Cutting force is one of the primary factors that can cause failure in gear cutting machine operation. Gear milling processes that occur during the continuous generation of gear surfaces are characterised by significant unevenness of the cutting force, as well as periodic jumps in the cutting force and torque. This is due to the peculiarity of the cutting scheme in conditions of gear continuous generative. These cyclical jumps in cutting force can cause microcracks, delamination, chipping and breakage of tool blades, resulting in a loss of machine tool performance. Therefore, the problem addressed in this article is highly relevant to modern production. Research Methodology. Cutting forces prediction was performed using graph-analytical modelling of cut layer parameters and the Deform 2D simulation modelling system. Scientific novelty. The study’s results provide a solid foundation for selecting optimal conditions for gear cutting processes using the radial-circular method, while also suggesting ways to prevent carbide gear cutting tool breakage and ensure the smooth operation of gear milling machines.