scope:

Power skiving is an emerging gear cutting process that has been identified as a process that can provide a step change in the production rate of high precision internal and external involute gear forms. The continuous generating principle is the basis of the cutting process that ensures the increased throughput of the process that is significant for internal gears. The understanding of the loads applied in the cutting tool and the gear as well as the final characteristics of the gear machined through power skiving is of key importance in the optimization of the cutting process. The present research focuses on two strands, first the development of a novel CAD based simulation platform that is able to simulate the power skiving process and calculate the cutting forces and the resulting gear topography. The second strand includes the validation of the model with analytical and experimental data from literature. In depth, investigation in the quality of gears produced is presented as part of this study with a focus in the influence of key process parameters in the resulting gear quality. Through this study a series of process maps can be drawn that assist in the selection of the most productive parameters for machining involute gears.