Power Skiving – A Step Changing Manufacturing Process Applicable to Multifunctional 5-Axis Machine Tools
developing gear machining methods using multifunctional 5-axis machine tools with the expertise from collaboration with multiple partner companies. One machining method applicable to multifunctional machine tools is power skiving. This modern gear cutting process is gradually being adopted by industry, but its application is considered a secretive black art. The focus is to develop and quantify the capabilities and publicize this for the benefit of industry. The initial test geometry was a spur gear of 4.75-inch diameter and DP 6.5, which had teeth roughed and finished in 6 minutes 20 seconds, achieving a quality of AGMA 2015-A01 class A5 (AGMA 2000-A88 class Q12).
Further test geometries have been trialed, including helical gears, ring gears, and internal splines, to ascertain how process performance transfers to alternate geometries and what the key process variables affecting productivity and gear quality are. Software models have been developed to predict cutting forces and establish cutting parameters for new geometries in order to expedite the process development. A range of cutting parameter strategies has been employed to establish an optimal approach for enhanced quality and reduced vibration. Cutting tool life has also been established for a range of geometries and parameter sets with a view to quantifying the commercial viability of the process.
Power skiving offers great opportunities for production with step-changing productivity, particularly for internal gears, whilst offering high quality finishing capabilities and being applicable on a 5-axis machine tool with its inherent flexibility and multi-functionality.
Authors: Bethany Cousins, Chao Sun, David Curtis, Michael Farmery, Steven Staley, Ben Cook
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