undeformed chip

Aim. The aim of this paper is to create a 3D model of the undeformed chips produced during the cutting of an internal gear ring. By modelling the power skiving process, it is necessary to investigate the influence of various geometric and technological parameters on the thickness and cut area of the chips produced. Method. By simulating the gear turning process, it is possible to reproduce the cutting of the gear teeth and accurately determine the geometric parameters and the shape of the undeformed chip at each moment.

In this study, the process of tool plunging into the workpiece during external tooth cutting will be modelled. Cut-in is one of the most dangerous stages not only in gear turning, but also in any cutting process. The gear cutting process is analytically studied in terms of maximum chip thickness and, on this basis, recommendations for process design are offered. The developed simulation is able to calculate the appropriate cutting geometry for each revolution of the tool cut-in to the workpiece.

The results of modelling and investigation of external and internal gear-cutting processes using the power skiving method are presented. The principles of constructing a geometric model of undistorted chip formation are described, based on parameters from which cutting forces are calculated. It is found that, under identical conditions, the cutting force is three times greater when internal gears are cut than when external gears are cut. The influence of this force on the machining error is determined by the gear pitch parameter.