Time-Domain Analysis of Dynamics and Stability of Power Skiving Operation

Power skiving is a high-speed gear cutting process that has gained increasing interest from industry due its potential to enhance productivity in the field of gear manufacturing. However, the inherent flexibility of the tool and workpiece components make the process susceptible to unwanted vibrations if inappropriate process parameters - such cutting speed, axial feed rate, and cutting depth - are chosen. This paper describes the implementation of a time-domain simulation of dynamic deflection considering regenerative forces within a virtual model of power skiving. Combining previously developed kinematic and force prediction models with measured spindle-tool holder-tool assembly modal data, predictions of process vibrations and stability are made for trials with varying axial feed rates and cutting speeds. These predictions are compared to measured cutting forces from the same trials as performed on a DMG MORI NT5400DCG mill-turn machine tool.