Detection and visualization of chatter in gear hobbing based on combination of time and frequency domain analysis
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ORIGINAL ARTICLE
Detection and visualization of chatter in gear hobbing based on combination of time and frequency domain analysis Xiaoqing Tian 1
&
Ruofeng Chen 1 & Hong Jiang 1 & Fangfang Dong 1 & Lei Lu 1 & Jiang Han 1 & Lian Xia 1
Received: 5 June 2020 / Accepted: 20 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract This paper presents a method for the detection and visualization of chatter in gear hobbing based on a combination of time and frequency domain analysis of acceleration data. By analyzing the acceleration data of the workpiece rotation shaft, chatter was identified, and the relationship between the vibration of the workpiece rotation shaft of hobbing machine and profile deviation of machined gears was established. First, a hobbing cutting experiment was made with different cutting parameters; meanwhile, DH5922N dynamic signal test analysis system and DH311E acceleration sensors were used to collect acceleration data during the hobbing process. Then, the relationship between tooth passing frequency and chatter was established by time domain and frequency domain analyses; furthermore, variance and root mean square value of acceleration data were calculated to judge the magnitude of data fluctuation to indirectly reflect the stability of the machining process. Finally, by detecting the tooth profile deviation and analyzing surface topographies of machined gears, the relationship between vibration and gear machining quality was established: low vibrational level leads to better gear machining precision and surface topography. The research result can provide a theoretical basis for the accurate selection of machining parameters and excellent structural design of hobbing machine tools. Keywords Gearhobbing . Workpiece rotationshaft vibration . Time and frequency domainanalysis . Chatter . Surface topography
1 Introduction As the core mechanical parts, gears are widely used in industries and other fields such as automobiles, ships, aerospace, high-speed rail, energy equipment, and intelligent manufacturing. The quality and performance of gears determine the performance and reliability of equipment, and the gear industry has become the largest part of the general mechanical field. Gear hobbing is used as a rough or semifinishing process for gears; hobbing is more efficient than other processing technologies (such as gear shaping), so gear hobbing machine tools are widely used, and the number of hobbing machines currently accounts for 45–50% of
* Xiaoqing Tian [email protected] * Lian Xia [email protected] 1
School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, China
the total number. As a rough machining process, hobbing gear’s axial feedrate and radial cutting depth are large. It is difficult for a machine tool with poor rigidity and unreasonable structural design to ensure the machining precision of the hobbing machine. Therefore, improving the stability and processing precision of the hobbing machine, reducing gear production c
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