Cutting force prediction in gear shaping process using discrete solid modeller

This paper describes a summary of the research published in [1]. Gear shaping is the primary manufacturing method for creating internal gears and gears with geometric constraints that make other methods, such as hobbing, impossible. Gear shaping kinematics are modelled and cutting force prediction is achieved by extracting the cutter-workpiece engagement using a discrete multi-dexel based solid modeller. The two-dimensional chip geometry is reconstructed using the alpha-shape reconstruction method. The cutting edge is discretized into nodes with varying inclination, rake angles, and principal cutting directions. Finally, the cutting forces are estimated using the oblique cutting model. The estimated cutting forces match closely with measurements taken on a gear shaping machine tool.