Method for Optimizing the Tool and Process Design for Bevel Gear Plunging Processes

For manufacturing bevel gears, a special tool system consisting of cutterhead and removable blades produces multi-flank chips which are of complex, three-dimensional geometry. The objective of this thesis was to optimize the manufacturing process for continuous and discontinuous plunging for bevel gear cutting regarding tool life based on tool angles and process parameters. For this purpose, a wear model was developed that is based on the elastic deformation of the workpiece.