Load Parameters of the Gear Machining by Power Skiving and Their Influence on the Machining System

The study results for cutting gears by the Power Skiving method was presented based on a graphical and analytical model of chips and an analytical model of cutting force and torque. A methodology for modeling 3D chips and analyzing the cut layers of a disk cutter at the level of certain edges was developed. Based on the example under certain initial conditions, the capabilities of the developed models were shown to predict the load on a single tooth and the entire machine tool system during multi-tooth continuous cutting and the influence of power factors on the machining process. Two factors significantly influence the cutting force: the cross-sectional area and the cutting thickness. An increase in the cutting area proportionally increases the cutting force and the load on the system. The shear thickness affects the cutting force through its effect on the chip compression ratio: when the shear thickness decreases, the intensity of shear plastic deformation and cutting force increase. Shear intensity increases sharply at low chip thicknesses, characteristic of force shearing, so high cutting forces accompany this process.