FEM-supported simulation of chip formation and flow in gear hobbing of spur and helical gears

An integrated procedure for simulating the complicated chip formation and flow in gear hobbing is presented. The mathematical description of this manufacturing method is based on the calculation of penetrations between cutting teeth and gear gap, a solid modeling process and finally an implementation into a FEM code. Additionally, hobbing of spur gears and the four possible variations for manufacturing helical gears are investigated. A comparison of the calculated chips with the cut ones was conducted and revealed a sufficient similarity. Finally, visualization of phenomena such as of the chip collision with gear flanks during the chip flow in individual generating positions is provided.