Study of non-stationary cutting processes in power skiving

Abstract

The paper presents the results of the modelling and study of the cutting process in the cut-in phase during the machining of external gears by the power skiving. The studies were carried out on the basis of the previously developed graphical model of the cut layers and the model of the cutting force as a function of the chip cross-sectional area, the shear strength limit of the workpiece material, and the intensity of plastic deformation during cutting. The regularities of the cutting force in the cut-in phase of gear machining are shown for successive tool revolutions in four passes with a gradual increase in the depth of cut. It is shown that the peak values of the cutting force at the contact between the front face of the cutter and the face plane are two times higher than under the conditions of steady stationary cutting in a preformed gap. At the same time, the amplitude of the cutting force and its average value over the cut-in passes are 1.7–3.7 times and 1.2–1.5 times higher, respectively, than the corresponding values of these parameters for steady state cutting. It is these peak jumps in the cutting force that limit the maximum depth of the cut, number of passes, and axial feed. Based on the data obtained, recommendations were developed to modify the traditional gear cutting scheme in power skiving. It is proposed to use short tool strokes with a low cutting depth along the length of the cut-in path and, after forming a gap in this area, to cut at a full depth to the full height of the gear rim. The possibility of a significant reduction of gear machining time using the proposed scheme of technological operation is demonstrated.