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<p>The toroidal involute worm (TI worm) drive, consisting of an hourglass worm and an involute helical gear, is a critical component in heavy-duty power transmission. Existing manufacturing methods for TI worms rely primarily on conventional turning and milling processes, which result in low processing efficiency. Therefore, this study proposes a cutter design method and a skiving process using a conical cutter to enhance machining efficiency while maintaining necessary accuracy. First, the TI worm surface is determined as the enveloping surface of the worm gear. The cutting edge of the skiving cutter is then proposed as the intersecting curve between the rake plane and the barrel gear, where the barrel gear correctly meshes with the TI worm. By employing an iterative process, the generating rack model and the conical cutter flank are concurrently derived from the proposed cutting edge. Finally, a skiving model is formulated by synchronizing the enveloping and circular feed motions within a gear-hobbing CNC machine architecture to simulate the machining process and numerically assess geometry accuracy. The results demonstrate the effectiveness and practicality of the proposed approach.</p>

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A novel conical cutter design approach and skiving process for manufacturing multiple-thread toroidal involute worms

  • 期刊论文

  • 发表日期：

    2026年3月12日

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  • Trong-Thuan Luu,
  • Yu-Ren Wu

摘要

The toroidal involute worm (TI worm) drive, consisting of an hourglass worm and an involute helical gear, is a critical component in heavy-duty power transmission. Existing manufacturing methods for TI worms rely primarily on conventional turning and milling processes, which result in low processing efficiency. Therefore, this study proposes a cutter design method and a skiving process using a conical cutter to enhance machining efficiency while maintaining necessary accuracy. First, the TI worm surface is determined as the enveloping surface of the worm gear. The cutting edge of the skiving cutter is then proposed as the intersecting curve between the rake plane and the barrel gear, where the barrel gear correctly meshes with the TI worm. By employing an iterative process, the generating rack model and the conical cutter flank are concurrently derived from the proposed cutting edge. Finally, a skiving model is formulated by synchronizing the enveloping and circular feed motions within a gear-hobbing CNC machine architecture to simulate the machining process and numerically assess geometry accuracy. The results demonstrate the effectiveness and practicality of the proposed approach.