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<p>Accurately predicting the cutting load in gear skiving is crucial for optimizing cutting parameters, extending tool life, improving gear tooth surface quality. An analysis framework for dynamic cutting loads was proposed and the finite element analysis (FEA) model was also created to analyze time-varying characteristics of gear skiving cutting loads during the cut-in, stable cutting, and cut-out phases. Based on numerical simulations, the quantitative relationships between cutting parameters and dynamic cutting loads, including cutting force and torque, cutting temperature, and cutting edge stress, have been explored. The simulation results indicate that with changes in axial cutting position, the cutting force and torque rise during the cut-in phase, remain constant during stable cutting, and gradually decrease to zero in the cut-out phase. With rotation speed increasing from 500 to 1200 r/min, the tool cutting force and torque decrease, but the rate of decrease slows when the tool rotation speed reaches 800 r/min; the cutting temperature on the tool’s rake face exhibits a decrease-increase–decrease trend, while the cutting edge stress gradually decreases. The tool cutting force and torque rise by 30.6% for every 0.1&#xa0;mm/r increase in axial feed speed and by 12.6% for every 0.2&#xa0;mm increase in radial depth of cut, and both the cutting temperature and cutting edge stress are positively correlated with feed speed and depth of cut. The proposed cutting load analysis framework and simulation results for gear skiving can be applied for further optimization of cutting parameters.</p>

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Simulation and analysis of dynamic cutting load for gear skiving method considering different cutting phases

  • 期刊论文

  • 发表日期：

    2025年7月18日

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  • Zhonghai Xu,
  • Jicheng Sun,
  • Peng Wang,
  • Zhiwen Wu,
  • Ephrem Bekele Tesfa

摘要

Accurately predicting the cutting load in gear skiving is crucial for optimizing cutting parameters, extending tool life, improving gear tooth surface quality. An analysis framework for dynamic cutting loads was proposed and the finite element analysis (FEA) model was also created to analyze time-varying characteristics of gear skiving cutting loads during the cut-in, stable cutting, and cut-out phases. Based on numerical simulations, the quantitative relationships between cutting parameters and dynamic cutting loads, including cutting force and torque, cutting temperature, and cutting edge stress, have been explored. The simulation results indicate that with changes in axial cutting position, the cutting force and torque rise during the cut-in phase, remain constant during stable cutting, and gradually decrease to zero in the cut-out phase. With rotation speed increasing from 500 to 1200 r/min, the tool cutting force and torque decrease, but the rate of decrease slows when the tool rotation speed reaches 800 r/min; the cutting temperature on the tool’s rake face exhibits a decrease-increase–decrease trend, while the cutting edge stress gradually decreases. The tool cutting force and torque rise by 30.6% for every 0.1 mm/r increase in axial feed speed and by 12.6% for every 0.2 mm increase in radial depth of cut, and both the cutting temperature and cutting edge stress are positively correlated with feed speed and depth of cut. The proposed cutting load analysis framework and simulation results for gear skiving can be applied for further optimization of cutting parameters.