Abstract
Power skiving is a new machining process that allows the manufacturing of external and internal gears while achieving high throughputs. Although the process was first described during the nineteenth century, it is not until lately that advances in machine tool technology allowed for the process to be implemented on an industrial scale. This paper presents a novel simulation model that enables the accurate prediction of the non-deformed chip geometry, the form and dimensions of the chips produced during the cutting process as well as the characteristics of the gear gap. The simulation model is embedded on a CAD environment in order to take advantage of their increased accuracy. Through the simulation code, the virtual simulation of the manufacturing process is realised. The simulation model was verified with the use of analytical equations regarding the form of the gear. Chip geometry and dimensions for internal and external gears machined with different conditions are also presented.
Highlights
Manufacturing of precision internal and external gears is one of the most critical and complex applications in industry
The simulation model introduced in this research focuses on the simulation of the power skiving process, which has not been investigated in the context of CAD-based simulation
Simulations focused on validating the accuracy of the model by comparing the resulting gear geometry, after the end of the simulation, with the analytic equations of the involute curve for a given set of parameters
Summary
Manufacturing of precision internal and external gears is one of the most critical and complex applications in industry. Power skiving is a manufacturing process for generating internal and external gears. Guo et al [7] studied the cutting mechanism for machining gears with power skiving. This paper presents a novel approach for simulating the power skiving process using a CAD system. The simulation model introduced in this research focuses on the simulation of the power skiving process, which has not been investigated in the context of CAD-based simulation. Since the power skiving process is still not fully established as a machining process, the model would allow engineers to select the most appropriate cutting parameters for machining gears without the need for costly trials. The inclination angle can be chosen independently from the helix angle of the workgear and has a big impact on the cutting process and the geometry of the gear gap as well as the chip.
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