Simulation of the power skiving process for cutting an internal gear with modelling of undeformed chips

Abstract

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. A model of the workpiece and cutting tool was created in the CAD system environment and the position of the bodies relative to each other was determined with the highest possible accuracy. Results. Following the simulations, graphical dependencies of the change in thickness and area of the undeformed chip cross-sections on module, feed, tool position and tilt were produced. The nature of the influence of these parameters on the cup cutter blades was also determined. The scientific novelty and practical significance. The study makes it possible to analyse the dynamics of changes in the geometric dimensions of undeformed chips produced by each cutter blade and to identify the most stressed zones. Furthermore, knowing the complete chip information, it is possible to study the force characteristics of the cutting process on the blades, heat flows, calculate machining errors and predict tool wear. After a complete analysis of all the results of the Power Skiving process study, it is possible to recommend the optimum operating modes of the available equipment for a given gear, taking into account the number of teeth, their module and the workpiece material.