Calculation of the maximum chip thickness for a radial-axial infeed in gear hobbing

A numerical penetration calculation was used to simulate the radial-axial infeed in gear hobbing for different tool/workpiece combinations. Taking into account 20,000 simulations, a nonlinear regression analysis was performed to establish a mathematical equation, describing the maximum chip thickness as a function of the infeed angle and relevant gear, tool and process parameters. The equation was validated using a new set of simulation results. The calculated values are in good agreement with the simulated values. The developed equation allows the design of the radial-axial infeed according to the maximum chip thickness without the use of a simulation program.