Parametric modeling of uncut chip geometry for predicting crater wear in gear skiving

• Published in: Journal of materials processing technology Vol. 290; p. 116973
• Main Authors: Ren, Zongwei, Fang, Zhenglong, Arakane, Takuhiro, Kizaki, Toru, Nishikawa, Tsukasa, Feng, Yannan, Kugo, Junshi, Nabata, Eiji, Sugita, Naohiko
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.04.2021; Elsevier BV
• Subjects: CAD/CAM; Crater wear; Cutting parameters; Cutting wear; Design optimization; Design parameters; Gear skiving; Geometry; Parametric statistics; Rake angle; Sweep surface of cutting edge; Tool wear; Uncut chip geometry; Gear skiving; Uncut chip geometry; Crater wear; Sweep surface of cutting edge
• ISSN: 0924-0136; 1873-4774
• DOI: 10.1016/j.jmatprotec.2020.116973

In gear skiving, tool wear is one of the primary issues owing to the large thermomechanical cutting load. However, the effective rake angle and depth-of-cut can vary continuously throughout a single cut, leading to a complex uncut chip geometry that significantly hinders the understanding of the cutting characteristics and adds further difficulty to the prediction of tool wear. This study proposes a parametric modeling method for calculating the uncut chip geometry for each cutting pass. Developments in the rake angle and depth-of-cut (as subjected to an uncut chip) were comprehensively investigated with an aim to advance the understanding of the cutting characteristics during a single cut. Based on the uncut chip geometry, the crater wear was successfully predicted using the derived stress and temperature data, followed by a single-tooth skiving wear test verification. By comparing numerical and experimental results for crater wear, an error of less than 5 % was obtained in both depth and area. The proposed method provides a non-CAD/CAM-engine-software/environment-based alternative for calculating the process of an uncut chip geometry, clearly advancing the flexibility in further potential applications such as cutting parameter optimization and cutter design.