Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Abstract

Power skiving is a new gear cutting process that has been recognized to provide a step change in the production rate achieved in the machining of high-precision internal and external involute gears. The process is based on a continuous generating meshing between the workgear and the cutting tool. Understanding of the loads applied in the cutting tool, and therefore some of the sources of tool wear, have not been thoroughly understood. This paper presents a novel model that is able to predict with high accuracy the cutting forces in the power skiving process. The model is based on a solid modelling simulation algorithm that produces high-fidelity solid bodies that are used for the calculations. The results of the model have been experimentally validated. A series of process maps are also produced to assist in the identification of the optimal machining parameters.

Power skiving manufacturing process: A review

“…These were employed in a Kienzle model to predict cutting forces. Tapoglou computed the non-deformed 3D UCG and the cutting forces in a similar fashion in [25,26]. Besides, he found a good correlation comparing simulated force data with literature results.…”

“…In his latest work [26], Tapoglou investigated the effect of different feed rate, rake angle and inclination angle values on cutting force components and chip geometry. This allowed the author to draw interesting conclusions on the impact of each parameters on the process.…”

Technological Aspects of Manufacturing and Control of Gears—Review

“…The maximum chip thickness calculated analytically was compared with the simulated one, showing agreement between the results. The research presented by Tapoglou [26] focused on the development and validation of a CAD-based model for predicting cutting forces in power skiving. The model included all movements of the cutting tool and workpiece and was used to define chip and gear geometries using Boolean operations.…”

General Cutting Load Model for Workload Simulation in Spindle Reliability Test

“…The first kind of method is mainly based on the shear plane or shear deformation zone theory of orthogonal cutting, and the cutting force models of oblique edge cutting and practical three-dimensional milling are obtained through appropriate transformation [7]. The second method establishes a set of partial differential equations and the corresponding boundary and initial conditions describing the mechanical-thermal coupling of the machining process and then solves the equations by numerical algorithms, such as finite element, boundary element, or finite difference method [8]. The third method is usually based on the experimental data under different process parameters to establish the nonlinear exponential function relationship between cutting force and process parameters [9].…”