Advanced tooth profile roughing system (Innovating gear skiving with diamond-shaped edge tools)

Abstract

The gear skiving process involves a machining method wherein a skiving tool continuously machines a workpiece while rotating synchronously. This method proves to be efficient for machining internal gears, addressing challenges faced by conventional machining methods. With the increasing demand for various types of tooth profiles to accommodate the high-speed rotation of motors, there arises a need for enhanced capabilities in gear skiving processes. Traditionally, it has been challenging to machine a diverse array of tooth profiles using a single skiving tool due to its design specificity for each type of tooth profile. In response, this study endeavors to develop Computer-Aided Manufacturing (CAM) algorithms capable of facilitating the rough machining of various tooth profiles with a single skiving tool in gear skiving process. This makes it possible to rough various types of tooth profiles in a short time without special tools. To realize this goal, two novel methods have been proposed. One approach involves the utilization of a diamond-shaped edge skiving tool, while the other entails moving the skiving tool laterally for each depth of cut before tool feed. These proposed methods enable the gradual machining of various types of tooth profiles in accordance with their shapes. An algorithm has been developed to calculate the amount of lateral movement required for each depth of cut based on tool and workpiece specifications. To validate these methods, an experiment was conducted to machine an asymmetrical tooth profile using a diamond-shaped edge skiving tool. As a result, the amount of error in the machined tooth profile relative to the target tooth profile was within ±25 μm except for the root. In conclusion, this study successfully introduces a new gear skiving process method capable of roughing a diverse range of tooth profiles with a single skiving tool.

Keywords

• gear skiving process
• tooth profile
• machining
• analysis
• computer aided manufacturing (cam)
• insert chip