Influence of the gear geometry and the machine on the power-skiving cutter design

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1 PWS Präzisionswerkzeuge GmbH: Influence of the gear geometry and the machine on the power-skiving cutter design Author: Dr. Rainer Albert Fig. 1 As a method known for more than 100 years, power-skiving has until now only played a minor role since conventional power skiving machinery has not been able to work productively. This has changed with the introduction of high-performance spindles. Since these can be synchronized at very high rotational speeds, it is now possible to use this method at an extra-ordinarily high productivity. Moreover, the problems associated with tool profile calculations have been solved. As a result, the complex profiles for power-skiving can be calculated, and power-skiving cutters can thus be produced to very high accuracies. State of the art power-skiving machines can now run at table speeds of 1,000-2,000 rpm, which was not possible in the past. 1- Regarding power-skiving in general: The speed for power-skiving is the relative component of the peripheral tool speed in the direction of the workpiece axis (Fig. 2). With respect to feed rates, the process is kinematically equivalent to hobbing, e.g. the power-skiving cutter is essentially a multi-start gear hob with one tooth per start; we then also adjust the machine setting to a feed per workpiece rotation. The process has the advantage of high table speeds. The process has the disadvantage that it does not generate a natural chip distribution and that relatively high negative rake angles are generated at the tool tip exit; in order to compensate these, we are then forced to rely on a multi-pass machining strategy. It is then generally not possible to machine gears in one or two passes, as it is commonly done for hobbing. Fig. 2 Quelle Prof. Höfler Vorlesungsscript 86 / Werkzeug Technik / N 162 / 25 August 2017

2 Fig. 5: Collision of the tool s tooth tips and the tooth tips of the workpiece 2- Configurations Fig. 3: conical type. Two different types exist: Conical type Cylindrical type On the conical type (Fig. 3), the relief angle is incorporated into the tool design. These tools are centered in the machine. The advantages of these tools include an essentially symmetrical profile, the straight-forward positioning and control technology, and its high flexibility. The disadvantage is that the profile is not constant over the tool life. The axial crossing angle needs to be reground as required, Moreover, the tools have very low tool-life for complicated profiles, e.g. for protuberance profiles. A characteristic of cylindrical tools (Fig. 4) is that these do not have the relief angle incorporated into the design. The relief angle is generated with an off-center position of these tools in the machine. The advantages of this cylindrical type are the constant profile - even for complicated profiles when controlled by regrinding, the constant positioning in the machine when controlled by regrinding and its suitability for full-carbide configurations and for small module applications. The disadvantages are the complicated positioning and process technology. Moreover, the production of such a tool involves a rather problematic asymmetric profile that is not easy to manufacture or measure. But PWS has these issues well in hand. The tool design must also take into account the collision of the tool teethes with the workpiece. If the off-center configuration of this tool is selected too small, the tool s tooth tips can potentially collide with the tooth tips of the workpiece, thus destroying it (Fig. 5). Conical power-skiving cutters should be used when high flexibility is required and when the machine tool does not have the complex control technology required for cylindrical tools. Cylindrical tools should in turn be used for complicated profiles and on power-skiving cutters for small module applications and when made from solid carbide. 3- Power-skiving on gearing machines without tool change In this case, the tool is clamped into the tool spindle, and positioned with the appropriate axial crossing angle relative to the workpiece. The object for this tool is to finish the workpiece in several passes without a tool change. Our standard power-skiving cutters used for this kind of process are made of PM S 390 with an aluminum chrome nitride coating. But powerskiving cutters made of solid carbide with a similar coating are also conceivable. Power-skiving on gearing machines without tool change is recommended in the module range m < 2.5 mm, and for workpieces, which have to be only geared. 4. Power-skiving on machining centers with tool change In addition to power-skiving, a machining center can also perform other machining operations such as turning or milling (e.g. Fig. 7 from Pittler). In this Fig. 4: cylindrical type. Fig. 6: Power-skiving process without tool change. 87 / Werkzeug Technik / N 162 / 25 August 2017

3 avoid selecting combinations that result in a poor run-out and segmentation characteristics on the workpiece. The number of teeth must be selected to achieve sufficient overlap with alternating tooth engagement and good run-out characteristics. Fig. 7: PITTLER machining center. case, we preferably use insert powerskiving cutters for rough cutting processes (Fig. 8). These power-skiving cutters are fitted with standard inserts, so-called VBMT inserts, similar to those used for turning operations. The finish operation is then performed with tools made of PM S 390 plus an aluminum chrome nitride coating. shown in Fig. 10, but instead in such a way that the teeth have very high angular spacing to each other. Sufficient overlap in the gap must also be provided. This results in very good flank line characteristics and very good surface finishes. As shown in Fig. 11 and Fig. 12, it is also important (whenever possible) to Fig. 8: Insert power-skiving. 6. Unsupported Length and spindle diameter, primarily for internal gears The spindle diameter must be chosen such that it does not collide with the outside diameter of the internal gears after Power-skiving on machining centers with tool change should be used for large module ranges (m>= 3 mm to 8 mm) and when workpieces need to be produced with additional machining operations such as turning or milling. Fig Number of teeth It is important in this case to avoid number of teeth combinations that transfer the run-out deviation of the tool directly to the flank line (Fig. 9). The intended number of teeth combination must be selected such that the individual tool teeth do not engage sequentially into a workpiece gap, as Fig. 9 Fig. 11

4 the complete power-skiving path. The unsupported lengths must also be selected such that the spindle diameter does not collide with the gearing and the adjacent flange, or such that the workpiece clamp does not collide with the gearing or also with the workpiece blank, see Fig. 13. As a general rule, the ratio between unsupported length and spindle diameter should not exceed a value of 3:1. However, a L/D ratio of 5:1 can certainly also be used when custom spindles are used. These considerations primarily play a role for feasibility studies; they are needed to determine an appropriate axial crossing angle, and must also be applied when designing shaft tools. Unsupported lengths and spindle diameters internal gears have to be defined such that the axial crossing angle is basically selected as large as possible, while minimizing the projection length. 7. Parameters for the required speed of the workpiece spindle At a constant cutting speed, the required rotational speed essentially depends on the pitch circle diameter of the gear. It can also be influenced by the Fig. 12 axial crossing angle, but not significantly. The result is that very high workpiece rotational speeds need to be generated, primarily when machining pinions (Fig. 14). As a general rule, small gears (pinions) require high spindle speeds and should be machined on turning centers. Large gears (wheels) are well-suited for milling machining centers. 8. Feed rates and productivity As shown in Fig. 15, the feed rate can theoretically be increased by increasing the power-skiving cutter diameter. However this results in a higher torque load, primarily in case of internal gears, caused by the larger number of meshing teeth and is critical for dynamic strength. If the power-skiving cutter diameter increases, the cutting arc length and the chip volume increase, whereas the aim is to achieve short and thick chips. An analysis of the axial crossing angle shows that it has no important influence on the feed rate. However, at a constant chip thickness, it does have a significant effect on the axial feed rate. This statement applies to axial crossing angles of >12. The axial crossing angle is defined based on an analysis of the machining conditions, but also based on existing known sources of defects; it is equally influenced by tool costs. In summary, power-skiving cutter designs should be executed in the nominal diameter range from 75 mm to 125 mm. This keeps the machining arc somewhat limited, while also keeping the rake angle deviation small. A standard axial crossing angle can be defined at represents a workable compromise between good machining conditions and tool costs. 9. Chip load and rake angle deviations A practical method for calculating the axial feed rate can be represented in the analysis of the tool path of the tool tip, as shown in Fig. 17. The tool path can be described as an ellipse in the simplified 2D rendering in Fig. 18, which is the base to calculate the curvature diameter De. The chip thickness h1 and the rake angle deviation φ can be approximately calculated based on the curvature diameter De and a known cutting depth e and a known axial feed rate fx. Fig. 13 Fig / Werkzeug Technik / N 162 / 25 August 2017

5 Fig 16 Fig. 15 The defined parameters are depicted in Fig. 19. Preliminary statements can be made about the number of passes and the size of the axial feed rate by specifying workable values for the rake angle deviation φ and the chip thickness h1. Prior experiences have shown that the rake angle deviation φ should not exceed 45, and that the chip thickness should be range between 0.1 mm to 0.3 mm, depending on the chosen tool material. ( ) The intent should be to achieve an optimized chip shape, and to attain an optimized chip volume. The power-skiving cutter diameter and axial crossing angle essentially influence the axial feed rate as a function of cutting depth. Fig. 17 Fig. 18 The specifications and findings given in this article result in a tool design and in a process technology based on which a stable power-skiving process can be implemented on a suitable machine tool. Fig / Werkzeug Technik / N 162 / 25 August 2017

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