Modeling of dynamic cutting force in high-speed dry gear based on multifactor coupling

The manufacturing industry is demanding more ´green´ technology and low impact on our environment. Dry cutting technology, particularly high-speed dry hobbing cutting, as a green manufacturing process can save resources, reduce environmental damage and costs. This paper presents a study on the process optimization of high-speed dry gear milling with a flying cutter. The research takes factors such as the regenerate domino effect of milling librations and non-continuous cutting into account, and establishes a dynamic cutting force model of multifactor coupling for the machining system including machine tool, cutting tool and workpiece. It also carries out digital simulation using Matlab/Simulink to study the vibrational displacement and dynamic milling force in time domain. The models developed were verified through experimental cutting trials. The research showed that proposed models can accurately describe the relationship between the dynamic cutting force and various cutting parameters as well as the state of the tool´s librations of multifactor coupling for the system including machine tool, cutting tool and workpiece.