Investigation of the manufacturability of topological modifications using adapted kinematics for gear skiving

Abstract

Specifically designed modifications of the involute of gears can positively influence the excitation behavior and the load carrying capacity of the gear. The standard modifications are mathematically described by linear and quadratic functions. Modifications that can be described by functions of higher order are called topological modifications. Gears featuring topological modifications not only exhibit improved excitation behavior compared to gears with standard modifications, but also an improved load carrying capacity. Modifications are usually applied in the final manufacturing step, e.g. by generating grinding, profile grinding or hard skiving.A method for applying topological modifications to gear flanks using a kinematic adaptation of the gear skiving process is presented in this paper. For this purpose a converter was developed that enables a transfer of any kinematics to machine control in order to manufacture modifications using the gear skiving process. The skiving process involves the removal of material from the gear flanks using a cutting tool. By controlling the kinematic variables of the process, it is possible to selectively shape the gear flanks in a precise and controlled manner. This approach allows the design and manufacture of customized gear shapes that can improve the performance of the gear system. The effectiveness of the method developed in this work is demonstrated through the experimental application of topological modifications.