Definition of the geometric parameters of the undeformed chip at the cut-in stage when machining an external gear using the power skiving method

Abstract

In this study, the process of tool plunging into the workpiece during external tooth cutting will be modelled. Cut-in is one of the most dangerous stages not only in gear turning, but also in any cutting process. The gear cutting process is analytically studied in terms of maximum chip thickness and, on this basis, recommendations for process design are offered. The developed simulation is able to calculate the appropriate cutting geometry for each revolution of the tool cut-in to the workpiece. Using the designed cutter profile and transition surface, the depth of penetration of the tool into the workpiece can be calculated for discrete time and space intervals. Finally, the developed simulation was tested on a gear with an external gear crown. This article describes the kinematics of gear cutting at the plunging stage and the algorithm for its modelling. In the description of the gear cutting kinematics, a method for creating a gear cutting simulation model was presented. In addition, an analytical method for calculating the maximum chip thickness was applied and confirmed by simulation.