power skiving process

This article explores the formation of non-deformed chips during the cut-in of an internal toothed ring using the Power Skiving method. This pivotal stage of the cutting process poses significant hazards not only in gear cutting but also in any cutting operation. The study involved modeling the process at the initial stage for various technological parameters, including cut-in depth and number of working passes. To achieve non-deformed chips, a methodology developed for worm milling was applied.

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.