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16 Taxiarchis Belis and Aristomenis Antodiadis
and precisely measure the chip’s thickness and length in head hH and lH,TF in
CAD environment. This data is fed to the equation illustrated in figure 5 in
order to calculate the arc length a f
) . Determination of a f
) is very important due
to the fact that maximum wear depth has been observed by researchers in this
region [2], [3], [7]-[9]. The calculation method of chip thickness hf is similar to
hH. After hs and lH are determined for every generating position, data can be fed
to the wear prediction model. All the calculations above can be simplified by
the use of parametric design in CAD environment. In the first step the arc a f
) is
set as parameter. In the next step the section of the chip from point K to F as the
hob profile revolves is cut. In the chip produced hH and lH,TF can be easily
measure and the arc a f
) calculated precisely. The parameter is set at the
calculated value and the chips regenerated automatically. Thus, chip thickness
hf can be easily measured. The final step includes calculation of the equivalent
thickness hs. The upper part of figure 6 presents the variation of the chip
thickness for all the revolving planes in several generating positions. These
diagrams have been generated from the sequence of the chip thickness results
hH as mentioned above.
3.3. Development of the Wear Prediction Program
The gear flank wear determination program is implemented in MATLAB
high-level matrix array language.
Fig. 7 – The Graphical User Interface of the wear simulation program HOBWEAR.