Influence of tool eccentricity on surface roughness in gear skiving

• Published in: Precision engineering Vol. 63; pp. 170 - 176
• Main Authors: Ren, Zongwei, Fang, Zhenglong, Kobayashi, Go, Kizaki, Toru, Sugita, Naohiko, Nishikawa, Tsukasa, Kugo, Junshi, Nabata, Eiji
• Format: Journal Article
• Language: English
• Published: Elsevier Inc 01.05.2020
• Subjects: Power skiving; Surface roughness; Tool eccentricity error; Z-Map method; Power skiving; Surface roughness; Z-Map method; Tool eccentricity error
• ISSN: 0141-6359; 1873-2372
• DOI: 10.1016/j.precisioneng.2020.02.007

Gear skiving is a state-of-the-art technique for machining internal gears with high efficiency. Numerical simulation method being able to analyze the eccentricity error e of cutter is critical to the understanding on the formation of surface roughness in skiving process. In this work, we proposed a novel Z-map-based numerical model to calculate the surface of gear flanks with eccentricity errors up to 9 μm. Correlation between eccentricity error and gear flank profile was clarified by numerical simulation and supported by experimental verification. The results show that the eccentricity error imposed a low-frequency motion during the generation of scallop height, leading to a surface roughness with a maximal error about four times that of the theoretical roughness. The e-induced scallop height became the majority factor account for variation of surface roughness when e exceeds 1.4 and 2.3 μm for feed rates of 0.4 and 0.8 mm/rev, respectively. The experimental result further supported the capability of proposed simulation model in providing detail surface features of gear flanks in skiving process. •A novel power skiving model considering eccentricity error has been established.•The surface characteristics of gears have been evaluated numerically and experimentally.•The effects of tool eccentricity error and feed rate on gear surface are revealed, respectively.