SIMULATION OF UNDEFORMED CHIP FORMED DURING CUTTING FOR INTERNAL CROWN TOOTH BY THE "POWER SKIVING" METHOD

Abstract

Today, the world's leading enterprises engaged in the manufacture of gear wheels increasingly use the Power Skiving method of cutting the gear crown on the wheel. This modern method allows you to process wheels with an external and internal crown, both spur and helical, as well as cut slots on shafts or hubs. This technology combines elements of turning and milling and ensures a very short production time. However, every year this method is increasingly improved, and in terms of its kinematics it is very complex and requires precise calculations. Determining the exact position of the tool and the workpiece at each moment of time is necessary for synchronizing movements during cutting. The principle of building an undeformed chip when cutting an internal straight-tooth crown by the Power Skiving method is shown. Section parameters for chip sections are obtained. They are the basis for modeling and calculating the values of cutting forces, friction, the necessary work that is needed to eliminate the allowance, heat flows that occur during cutting, the intensity of tool heating, temperature and wear of the tool, simulation of oscillations and dynamic processes. Complete information about the size and shape of the sheared layers, their size in different sections of the tooth at each moment of the cutting time is necessary for the description of various interrelated and interdependent deformation and contact processes. The established regularities of their continuous cyclical change during the revolution of the cutting tool are required for a comprehensive reproduction of the processes that occur during the cutting process of the toothed crown. A complex system of grapho-analytical, mathematical and computer modeling of this process has been developed for such a task. Kinematics is taken into account and the patterns of cutting-forming processes are reliably reproduced. The application of the grapho-analytical method of constructing sections for an undeformed chip is presented, which made it possible to establish its geometry and main characteristics, as well as to obtain a 3D model. Adequate models of chip formation are obtained. Quantitative estimates of parameters for slices in the process of Power Skiving are analyzed.