Understanding local cutting features affecting surface integrity of gear flank in gear skiving

• Published in: International journal of machine tools & manufacture Vol. 172; p. 103818
• Main Authors: Ren, Zongwei, Fang, Zhenglong, Kizaki, Toru, Feng, Yannan, Nagata, Tetsu, Komatsu, Yoshito, Sugita, Naohiko
• Format: Journal Article
• Language: English
• Published: Elmsford Elsevier Ltd 01.01.2022; Elsevier BV
• Subjects: Burnishing; Deformation effects; Design optimization; Gear skiving; Integrity; Level contour method; Local cutting features; Mathematical analysis; Misalignment; Plastic deformation; Rake angle; Recrystallization; Strain hardening; Surface integrity of gear flank; Thickness; Uncut chip geometry; Gear skiving; Level contour method; Uncut chip geometry; Local cutting features; Surface integrity of gear flank
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2021.103818

In gear skiving, large variations in cutting features significantly affect the cutting condition and surface integrity of a newly formed gear flank (NGF). This study aimed to improve the understanding of the effects of local cutting features on the surface integrity of approach and recess NGFs from the resulting microstructure produced by the multiple radial-infeed (MRI) strategy. For the first time, the boundary of the NGF regime and associated local cutting features were calculated from the uncut chip geometry (UCG) using a novel boundary-based level contour method. The theoretical and experimental results revealed that the local rake angle and uncut chip thickness are the most influential factors altering the plastic deformation conditions of the approach and recess NGFs. For the finishing pass, the uncut chip thickness developments within approach and recess NGFs were elucidated, showing the burnishing regime dominated the recess NGF formation. The strain–stress characteristics of the recess NGF show the strain-hardening effect due to the severe plastic deformation. Kernel average misorientation mapping showed a partial reduction in the misorientation angle under the recess NGF. This points to the accumulated deformation in the interaction between successive skiving passes further facilitating the localized recrystallization. Proposed local cutting feature calculations can be applied for further kinematic parameter optimization and MRI infeed rate design. [Display omitted] •Boundary of the newly formed gear flank is derived from the uncut chip geometry.•Calculation method for local cutting features is proposed to clarify the skiving process.•An adequate analysis on gear flank formation is achieved by the clarification of local cutting feature.•Mechanism on the surface integrity alteration between approach and recess flanks is clarified.