Study the method of thermal frictional treatment of tooth gap for large-modular cylindrical gears
Tattimbek G. Sherov K.D. Absadykov B.N. Sikhimbayev M.R.
2025North Caucasian Institute of Mining and Metallurgy, State Technological University
Sustainable Development of Mountain Territories
2025#17Issue 1350 - 361 pp.
Introduction. Traditional machining methods for these components often face challenges related to high labor intensity, tool wear, and insufficient surface quality, especially when producing tooth gaps. The thermofrictional treatment method offers a promising alternative to improve efficiency and surface characteristics without compromising structural integrity. The aim of this study is to evaluate the feasibility and effectiveness of thermofrictional treatment in machining the tooth gaps of large-modular cylindrical gears, replacing the conventional rough milling stage with a more resource-efficient approach. Materials and methods. Experimental trials were conducted on 40Х steel blanks. Surface roughness was measured using a portable profilometer TR 100. The process was modeled using DEFORM 3D software. Cutting parameters included feed rates (S) from 0.13 to 2.08 mm/rev and spindle speeds (n) from 200 to 2000 rpm. Results. Experimental findings revealed that feed rate is the dominant parameter influencing surface roughness. Increased feed results in higher surface irregularity, while excessive reduction reduces processing efficiency. Higher spindle speed improves surface finish due to more stable chipformation. Optimal conditions were identified as S = 0.52 mm/rev and n = 2000 rpm. Simulation results showed that increasing spindle speed raises contact temperature (up to 2660°C) while reducing the depth of thermal penetration into the workpiece, resulting in localized thermal effects. Discussion. The study confirms that thermofrictional processing effectively replaces conventional rough milling, offeringacceptable surface quality and reduced manufacturing complexity. The thermal behavior at the interface plays a crucial role in achieving the desired surface integrity and must be controlled to avoid subsurface damage. Conclusion. Thermofrictionaltreatment using a specially developed disc cutter can be effectively applied to machine tooth gaps in large-modular cylindrical gears, achieving the required surface roughness while improving process efficiency. Resume. The method provides a viable and energy-efficient alternative to traditional machining operations for heavy-duty gear components. These results can be applied in gear manufacturing and repair facilities serving the mining and heavy equipment sectors. Further research should focus on analyzing hardness changes in the treated layer and optimizing heat distribution for various steel grades.
friction cutter , large-module gear wheel , roughness , temperature , thermal friction treatment , tooth recess
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S. Seifullin Kazak Agro-technical Research University, Astana, Kazakhstan
K.I. Satbayev Kazakh National Research Technical University, Almaty, Kazakhstan
Karaganda University of Kazpotrebsoyuz, Karaganda, Kazakhstan
S. Seifullin Kazak Agro-technical Research University
K.I. Satbayev Kazakh National Research Technical University
Karaganda University of Kazpotrebsoyuz
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