Abstract In the machining process, prediction of the cutting force is the key to cutting simulation and optimization. Specially, for the face milling of the spiral bevel gear, the un-deformed chip varies during the process due to the complicated generating kinematics, bringing great challenge to the prediction of cutting force. Regarding this, with a thorough investigation carried out, it is found that the un-deformed chips can be summarized as six cases and described by quadratic polygon interpolation. On such basis, a highly efficient and accurate analytical cutting force prediction model for generated face-milling spiral bevel gear is proposed. Compared to the Boolean operation based method, the proposed method is faster; compared to the chip-simplify method, the method is more precise; and compared to the semi-analytical method, the method is more effective as the chip forming rule is fully considered, which in turn simplifies the operation. Further, the proposed method is validated through both FEM simulation and cutting force experiment with a tolerance within 10%.

中文翻译：

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螺旋锥齿轮端面铣削切削力预测的半解析模型

摘要 在加工过程中，切削力的预测是切削仿真和优化的关键。特别是对于螺旋锥齿轮的端面铣削，由于产生运动学​​复杂，加工过程中未变形切屑变化很大，给切削力的预测带来了很大的挑战。对此，经过深入调查，发现未变形的切屑可以概括为六种情况，并用二次多边形插值来描述。在此基础上，提出了一种高效、准确的生成面铣螺旋锥齿轮解析切削力预测模型。与基于布尔运算的方法相比，该方法速度更快；与chip-simplify方法相比，该方法更精确；与半解析法相比，由于充分考虑了切屑形成规律，该方法更加有效，从而简化了操作。此外，所提出的方法通过有限元模拟和切削力实验得到验证，公差在 10% 以内。