ABSTRACT

Within this paper, the power skiving process of gear tooth machining was evaluated and developed with respect to cutting tool orientation. The impact of minor variations to the orientation of three factors related to the cutting tool were explored to determine the effect of cutting tool orientation on the output metrics of finished gear geometrical characteristics within the design space.

The aim of the study was to use the knowledge gained to develop a statistical based model with the ability to predict how adjustments to the chosen three factors would affect the quality of the gear features produced. This would theoretically allow for tooling errors (or indeed other repeatable errors) to be counteracted through positional changes within the power skiving process based on the design space of the trials.

The initial phase of the work utilized a Design of Experiments (DoE) methodology. This was used to assess the gear quality implications of alterations made to the three chosen factors related to the tool position when power skiving with tooling made to drawing specifications. The statistical-based model fit was formed of quadratic, interaction and independent coefficients analyzed to map responses in the gear. Following the experimental trial, the statistical model was reviewed and refined. Ahead of a validation trial, predictions were made to estimate the results of a final block within the DoE which proved the statistical model fit to possess a high level of predictive power.

In most cases responses were within 10% of the predicted tolerance and all results were within 50%. This was extremely encouraging, and the work confirmed that a statistical based approach could be adopted to support future predictability of the process.

Author(s): Bethany Cousins, David Curtis, Michael Farmery, Ben Cook

ISBN: 978-1-64353-160-1