Simulative approach to investigate the influence of tool deviations on the effective cutting conditions in gear skiving

In the course of electromobility the demand for resistant and high-precision internal gears is increasing. Gear skiving is a complex manufacturing process offering a good compromise of productivity and flexibility for this application. The process is characterized by a strong variation of the effective cutting conditions across the tool profile and the engagement. Therefore numerical models are required for profound process design. However, common methods for calculating the effective cutting conditions do not take deviations of tool teeth into account. This work presents a simulative approach to investigate the influence of tool deviations on the effective cutting conditions in gear skiving. An existing penetration calculation is extended to include radial and axial runout and pitch deviation of the tool teeth. An exemplary simulation study is conducted to analyze their influence on the effective cutting parameters with a focus on the detection of extreme values. It is shown that pitch deviations have a significant effect on the uncut chip thickness and the effective rake angle. This effect can be further amplified or mitigated by radial runout deviations.