Integrated mathematical approach for design and manufacturing of power-skiving tool for interference-free involute internal gear cutting

Abstract

Power-skiving is one of the most effective methods for producing internal gears. However, without the support of corresponding CNC NC code conversion software, it is difficult to manufacture power-skiving tools using traditional tool grinding technology. Accordingly, manufacturing methods for power-skiving tools must be developed from scratch in accordance with basic tool design principles. Due to the particularity of the machining kinematics of power-skiving tools, special attention must be paid to avoiding cutting interference between the flank face of the cutter and the gear tooth surface during the machining process. This consideration greatly increases the time and complexity of the design process. Accordingly, this study presents a systematic mathematical approach for the design and manufacturing of power-skiving tools. A four-step method is first proposed for the design of interference-free power-skiving tools for the machining of involute internal gears. A mathematic approach is then presented for generating the NC code required to grind the clearance surface and rake surface of the designed tool using a five-axis CNC grinding machine. The simulation and experimental results confirm the feasibility of the proposed approach.