Abstract
Tool design is one of the key factors that restrict the development of gear skiving technology since the design principle does not correspond to the cutting principle. The existing skiving tool cannot achieve ideal machining accuracy and reasonable cutting angles. In view of this, some research has been done in this paper. Firstly, the skiving principle is investigated essentially according to the skiving motions. Then, the principle of tool design is analyzed based on the theory of conjugate surface, and a new tool design method is proposed to match the skiving principle. For this, all the skiving patterns for various kinds of workpieces are enumerated and summarized to abstract a normalized skiving model. Based on this, the mathematical model of the conjugate surface is then derived to lay the foundation for tool design. Then, the design methods of cutting edge, rake face, and flank face are proposed. An example is presented at last, and the cutting simulation is conducted. The result proves that the proposed methods are correct and valid. The theoretical research in this paper could promote the improvement of skiving tools.
Highlights
Gear skiving [1, 2] is a new processing technology which has been realized just from the beginning of the 21st century with the development of numerical control technology
The skiving tool is basically designed according to the envelope theory. e common slotting tool is even directly used for gear skiving in some cases [3]. e existing skiving tools usually have the following problems in engineering: (1) the machining accuracy of the two sides of the workpiece is inconsistent [4, 5]. (2) Interference is easy to occur in the cutting process [6, 7]. (3) e cutting edge has theoretical shape error and the machining accuracy after tool regrinding would be obviously different from that before regrinding [8, 9]. (4) e tool wear would be fast and uneven if the tool and skiving parameters [10, 11] were unreasonably set
The skiving principle is investigated firstly from the view of the essence of skiving motions. en, the tool design principle is analyzed based on the theory of conjugate surface, and a new tool design method is proposed to match the skiving principle
Summary
Gear skiving [1, 2] is a new processing technology which has been realized just from the beginning of the 21st century with the development of numerical control technology. The theory of conjugate surface [12, 13] is the most commonly used Based on this theory, some error-free design methods [14, 15] for the cutting edge have been proposed. It is necessary to ensure that the shape of the cutting edge is correct without overcutting or undercutting and easy to achieve the required accuracy when tool manufacturing or regrinding. The cutting edge is picked from the conjugate surface based on the essential principle of gear skiving to ensure that it is error-free. A new tool design method is proposed in Section 3 to achieve error-free cutting edge and tool faces with reasonable and even working angles.
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