Computer Numerical Control Machining Simulations and Experimental Analysis of a Novel C-Gear

Abstract

C-gear is a novel gear transmission system, with no existing special machining and cutting tools to realize its construction. In this study, we employed a 5-axis computer numerical control (CNC) machining center to construct a C-gear, while solving the prototype manufacturing problem at the experimental research stage. We deduced the C-gear mathematical model and studied the three-dimensional (3D) modeling methods based on the analysis of its generation principle. The C-gear processing technique using the 5-axis CNC machining center and the tool path designs were established using the VERICUT and MASTERCAM softwares, and the C-gears were experimentally constructed. The maximum overcut and residual of the gear positioning hole surface were both found to be 0.094 mm. Moreover, the maximum overcut on the tooth surface and root were 0.02 and 0.03 mm, respectively, and the maximum residual on both the tooth surface and root was 0.03 mm. The machining overcuts and residual amounts of the proposed method were better than those of reference [14]. The existing overcut and residual errors included the errors generated by surface fitting during the 3D modeling of the gears. Therefore, the machining errors of the physically constructed tooth surface are expected to be smaller than the theoretical value, suggesting a high feasibility of the proposed method to realize the machining of C-gears.