Three-dimensional modeling of gear skiving kinematics for comprehensive process design in practical applications

Abstract Gear skiving is a high-performance gear manufacturing process, whose design typically requires numerical models to calculate the multivariate cutting conditions. Since simulation software for gear skiving is still commercially hardly available, two-dimensional approximations have widely been used by gear manufacturers to calculate the extreme values of cutting conditions. In this work, a three-dimensional model for the calculation of cutting speed, rake angle and uncut chip thickness extreme values is presented and validated by penetration volume simulations. The comparison with the two-dimensional approaches shows a significant benefit in model accuracy over a wide parameter range and its suitability for practical applications.