Chip geometry and cutting forces in gear power skiving

This paper describes a new virtual model for predicting the uncut chip geometry and cutting forces in power skiving, which is a high-speed, versatile gear cutting process. The developed kinematic model is applied in a dexel-based solid modeling engine to extract three-dimensional uncut chip geometry, from which the two-dimensional cross section is obtained via Delaunay triangulation. Cutting velocities along discretized cutter edges are calculated and used to determine the effective rake and oblique angles. Then, force predictions are made using the oblique cutting model and validated using measurements from power skiving trials performed on a DMG MORI NT5400DCG mill-turn machine.