Structure Design Of Skiving Cutter And Error Analysis Of Skiving Processing

The main manufacturing method for cylindrical gear are gear hobbing, gear shaper, milling, gear broaching. But in view of internal gear, the above-mentioned manufacturing method can’t meet the demand of high precision, efficiency, environmental protection. Gear skiving can be used for processing internal and external cylindrical gear, especially be suitable for fine-module internal gear. Gear skiving has many advantages, such as high precision, efficiency, low cost and so on. Many researches on the principle, cutting tool, CNC machine of gear skiving have been taken up to now, but there are still a long way to meet the large scale application. As the important part of the gear skiving, the skiving cutter design theory is the main factor to push the skiving tenchologhy. Moreover skiving machining error is related to gear tooth surface machining precision, the reaserch on the skiving processing will be useful for improving the machining accuracy, and influence the skiving application. The skiving cutter structure is designed based on the helical gear shaper cutter in this paper. The machining gear tooth surface calculation model is established based on the skiving cutter blade, then the cutter error and machine tool adjutment error are analyzed, These works would provide support theory and tools for the intensive study on issues such as machining error analysis and error compensation.Firstly, the skiving processing principle and generating gear of skiving cutter is analyzed, and the skiving motion model and machining coordinate are established. According to the crossed helical gear meshing principle, the basic parameters of generating gear are determined. The contact-trace is calculated. The the skiving process is analyzed from the point of geometrical figuration, then the two cutting effect and chip removal way are presented.Secondly, the skiving cutter structural design critericon is put forward based on the skiving processing principle. And then the structure of the cutter rack and flank face are designed based on the helical gear shaper cutter. The calculation model of cutter blade is established. The cutting edge error is corrected with the adjustment of pressure angle and base radius. The skiving cutter 3D model is built with Pro/E.Thirdly, the skiving processing error is analyzed. Based on the conjugation principle of curves and surfaces, the transverse tooth profile calculation model including the machine tool adjutment error is established using the cutter blade. The tooth profile error calculation method is put forward. The effect on the tooth profile error of the cutter error and machine tool adjutment error is analyzed, an then the error compensation for profile error is prensented based on the machine tool adjustment parameters.Finally, based on the cutter and motion model the NC simulation of skiving processing is given using VERUCUT software. The 3D model of cutter and machine tool are built by Pro/E, the NC code is generated through MATLAB, the skiving NC simulation can be doen after the above files are improted in VERUCUT. Through the analysis of the simulation results, the correctness of the designed skiving cutter and error analysis method are verified.