Fraunhofer Institute for Machine Tools and Forming TechnologyPower Skiving is a continuous hobbing manufacturing process characterized by high productivity combined with great geometric flexibility. The process thus combines the advantages of gear hobbing and gear shaping and is particularly suitable for machining internal gears or collision-critical gears in the vicinity of interference contours
Power Skiving with a geometrically defined cutting edge is a typical process for roughing or soft machining of gears. However, it can also be used for fine machining. In contrast to other gear cutting processes with a specific cutting edge, Power Skiving is characterized by highly variable cutting conditions during cutting engagement. This concerns in particular the effective rake and clearance angles, but also speed and force vectors. For these reasons, tool and technology design play a decisive role.
For targeted machining optimization, a process model was developed at Fraunhofer IWU and transferred to the "SkiveAll" software. With this software, the tool profile and the corresponding setting parameters can be calculated, taking into account the characteristic technology parameters, such as the axis cross angle and the workpiece geometry to be machined. In addition, the kinematics and tooth engagement can be simulated. As a result, the user receives statements on the optimum process angle as well as the effective speeds and cutting geometries.
An important research focus is the investigation of different infeed strategies. Their design has a significant influence on the productivity and process reliability of Power Skiving. The aim is to determine individual setting and cutting parameters for each individual cut and thus optimize the main time and tool tool life. With the aid of a wide variety of cutting tests, we can verify the design results, evaluate different infeed strategies and determine tool life. In the future, the process will be further developed for hard fine machining.