<p>Gear skiving is an efficient and precise method for gear manufacturing. Traditional conical skiving tools feature a structural relief angle on the flank and a plane rake face, which often leads to inconsistent accuracy after regrinding and an unreasonable working rake angle. This paper proposes a novel design method for cylindrical gear skiving tool with uniform working rake angle based on origin offset. A motion model for offset gear skiving is established, and the conjugate contact relationship between the tool and the workpiece is derived. The cutting tool is constructed by a free-form rake face and a helical flank face. The working rake angle is controlled to be uniform, and the flank face is confirmed to have no interference through sweeping trajectory calculation. A multi-physics coupling simulation model for cutting forces and temperature field is developed using finite element method. The results demonstrate that, compared to the conventional plane-rake-face tool, the proposed tool with a curved-rake-face significantly reduces cutting force fluctuations and peak temperature, leading to enhanced tool life, improved machining stability, and superior gear accuracy. A cutting experiment verified the correctness and effectiveness of the proposed tool design method.</p>

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Design and cutting performance analysis of cylindrical gear skiving tool with uniform working rake angle

  • Jiaxue Ji,
  • Peng Wang,
  • Rui Xue,
  • Tiegang Wang,
  • Kan Xing,
  • Jiawei Li

摘要

Gear skiving is an efficient and precise method for gear manufacturing. Traditional conical skiving tools feature a structural relief angle on the flank and a plane rake face, which often leads to inconsistent accuracy after regrinding and an unreasonable working rake angle. This paper proposes a novel design method for cylindrical gear skiving tool with uniform working rake angle based on origin offset. A motion model for offset gear skiving is established, and the conjugate contact relationship between the tool and the workpiece is derived. The cutting tool is constructed by a free-form rake face and a helical flank face. The working rake angle is controlled to be uniform, and the flank face is confirmed to have no interference through sweeping trajectory calculation. A multi-physics coupling simulation model for cutting forces and temperature field is developed using finite element method. The results demonstrate that, compared to the conventional plane-rake-face tool, the proposed tool with a curved-rake-face significantly reduces cutting force fluctuations and peak temperature, leading to enhanced tool life, improved machining stability, and superior gear accuracy. A cutting experiment verified the correctness and effectiveness of the proposed tool design method.