Simulation analysis of residual stresses in cutting of spiral bevel gear tooth surfaces by the forming method
DAI Pengju
ZHANG Fengshou
MENG Qinghui
Abstract：[Objective]To investigate the influence of the cutting speed,the depth of cut,and the feed rate on the residual stress of tooth surfaces during the form cutting of spiral bevel gears,a three-dimensional oblique cutting simulation model was established based on the characteristics of form cutting technology.[Methods]Single-factor and response surface methods were used for simulation to analyze the impact of each cutting parameter on the residual stress of the tooth surface.A response surface prediction model was developed to determine the optimal combination of cutting parameters,which was then validated through tests.[Results]The results indicate that the machined tooth surface is initially characterized by tensile stress,which rapidly transitioned to compressive stress along the depth direction before gradually diminishing to zero.Increasing the cutting speed enhances the surface residual tensile stress while slightly reducing the maximum internal compressive stress.The feed rate exhibites the most significant impact:the higher feed rate markedly increases the residual stresses on both the surface and within the hardened layer,accompanied by the greater stress penetration depth.Variations in the cutting depth demonstrates the minimal influence on the residual stress.The maximum relative error between predicted and test values of the tooth surface residual stress is 6.17%,validating the feasibility of simulation-based residual stress prediction in cutting processes.
Keywords：Spiral bevel gearOblique cuttingFinite element simulationResidual stressResponse surface methodology
Publication Date：2025-05-15
Online Publishing Date：2026-09-12(First online date of this platform, not the publication date of the document)
Pages：8( 93-100 )