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Technical Brief

Basic Study on Calculation of Cutting Forces Useful for Reducing Vibration in Skiving

[+] Author and Article Information
Tomokazu Tachikawa

Aisin Seiki Co., Ltd.,
2-1 Asahi-machi, Kariya,
Aichi 448-8650, Japan
e-mail: t_tachi@ped.aisin.co.jp

Daisuke Iba

Department of Mechanical Engineering,
Kyoto Institute of Technology,
Goshokaido-Cho, Matsugasaki, Sakyo-ku,
Kyoto 606-8585, Japan
e-mail: iba@kit.ac.jp

Nobuaki Kurita

Aisin Seiki Co., Ltd.,
2-1 Asahi-machi, Kariya,
Aichi 448-8650, Japan
e-mail: nkurita@ped.aisin.co.jp

Morimasa Nakamura

Department of Mechanical Engineering,
Kyoto Institute of Technology,
Goshokaido-Cho, Matsugasaki, Sakyo-ku,
Kyoto 606-8585, Japan
e-mail: nakamura@mech.kit.ac.jp

Ichiro Moriwaki

Department of Mechanical Engineering,
Kyoto Institute of Technology,
Goshokaido-Cho, Matsugasaki, Sakyo-ku,
Kyoto 606-8585, Japan
e-mail: ichi@mech.kit.ac.jp

1Corresponding author.

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received November 4, 2016; final manuscript received August 2, 2017; published online August 30, 2017. Assoc. Editor: Hai Xu.

J. Mech. Des 139(10), 104501 (Aug 30, 2017) (6 pages) Paper No: MD-16-1740; doi: 10.1115/1.4037625 History: Received November 04, 2016; Revised August 02, 2017

In order to improve the accuracy of skived gears by means of reducing vibrations that are often observed during the cutting process, a simple model for calculating the cutting forces of skiving process is presented and also its effectiveness was discussed. The model is characterized by simple geometrical calculations, and the cutting forces were assumed as sum of vectors that represent the penetration of cutting edges. In the model, multiple cutting edges that are simultaneously meshing with the workpiece were considered. Distinguished oscillating frequencies of the calculated cutting forces and the natural frequencies of the clamped workpiece and of the cutter were carefully analyzed in order to predict the cutter rotation speed that was most likely to reduce undesired vibrations. Processing experiments conducted at several cutter rotation speeds showed that the predicted cutter rotation speed which could significantly reduce undesired vibrations was very effective and enabled the quality of a skived gear to be improved. Consequently, the proposed calculation model was enough effective and useful for operation conditions such as cutter rotation speed being determined.

FIGURES IN THIS ARTICLE
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Copyright © 2017 by ASME
Topics: Vibration , Cutting , Gears
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References

Terashima, K. , and Ueno, T. , 1978, “ Numerical Analysis of Hobbing in Unified Space,” Trans. JSME, 21(155), pp. 907–914 (in Japanese). [CrossRef]
Galczyński, R. , 1984, “ The Effect of Hob Wear of the Level of Vibration Generated in Hobbing,” Int. J. Mach. Tool Des. Res., 24(4), pp. 295–309. [CrossRef]
Kojima, M. , 1973, “ On Clearance Angles of Skiving Cutter—Part 1: Helical Type Cutter for Internal Spur Gear Skiving,” Trans. JSME, 39(323), pp. 2257–2263 (in Japanese). [CrossRef]
Kojima, M. , 1974, “ On Clearance Angles of Skiving Cutter—Part 2: Spur Type Cutter for Internal Helical Gear Skiving,” Trans. JSME, 40(330), pp. 585–590 (in Japanese). [CrossRef]
Schulze, V. , Kühlewein, C. , and Autenrieth, H. , 2011, “ 3D-FEM Modeling of Gear Skiving to Investigate Kinematics and Chip Formation Mechanisms,” Adv. Mater. Res., 223, pp. 46−55. [CrossRef]
von Pittler, W. , 1910, “ Verfahren zum Schneiden von Zahnrädern mittels eines zahnrad-artigen, an den Stirnflächen der Zähne mit Schneidkanten versehen-en Schneidwerkzeuges,” Germany patent application.
Moriwaki, I. , Nakamura, M. , Hasegawa, T. , Funamoto, M. , Uriu, K. , Murakami, T. , Nagata, E. , Kurita, N. , Tachikawa, T. , and Kobayashi, Y. , 2013, “ Tooth Geometry Design of Cylindrical Skiving Cutter for Internal Gears,” VDI-Berichte, 2199(1), pp. 329–340. https://www.tib.eu/en/search/id/BLCP%3ACN086055117/Tooth-Geometry-Design-of-Cylindrical-Skiving-Cutter/?tx_tibsearch_search%5Bsearchspace%5D=tn

Figures

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Fig. 1

Axes layout of a skiving process

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Fig. 2

Schematic representations of cutter edge and flanks (left) and the unit vector that represents the direction of the cutting depth (right)

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Fig. 3

Schematic that shows the measurement of natural frequency: (a) schematic of measurement and (b) hitting points (black quadrangles) and measuring points (black circles)

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Fig. 4

Frequency responses of the clamped workpiece and the cutter: (a) clamped workpiece and (b) cutter

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Fig. 5

Calculated cutting forces and their power spectrums: (a) cutting force time series and its power spectrum in x direction, (b) cutting force time series and its power spectrum in y direction, and (c) cutting force time series and its power spectrum in z direction

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Fig. 6

Measured power spectrums of the workpieces in x, y, and z direction: (a) x direction, (b) y direction, and (c) z direction

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Fig. 7

Lead deviations of the skived workpieces

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