# Design and cutting performance analysis of cylindrical gear skiving tool with uniform working rake angle

## TL;DR

This paper introduces a new cylindrical gear skiving tool design that improves cutting performance and gear accuracy by maintaining a uniform working rake angle.

## Contribution

A novel cylindrical gear skiving tool design with a uniform working rake angle based on origin offset is proposed.

## Key findings

- The proposed tool reduces cutting force fluctuations and peak temperature compared to conventional tools.
- The curved-rake-face design improves tool life and machining stability.
- Gear accuracy is enhanced with the new tool design.

## Abstract

Gear skiving is an efficient and precise method for gear manufacturing. Traditional conical skiving tools feature a structural relief angle on the flank and a plane rake face, which often leads to inconsistent accuracy after regrinding and an unreasonable working rake angle. This paper proposes a novel design method for cylindrical gear skiving tool with uniform working rake angle based on origin offset. A motion model for offset gear skiving is established, and the conjugate contact relationship between the tool and the workpiece is derived. The cutting tool is constructed by a free-form rake face and a helical flank face. The working rake angle is controlled to be uniform, and the flank face is confirmed to have no interference through sweeping trajectory calculation. A multi-physics coupling simulation model for cutting forces and temperature field is developed using finite element method. The results demonstrate that, compared to the conventional plane-rake-face tool, the proposed tool with a curved-rake-face significantly reduces cutting force fluctuations and peak temperature, leading to enhanced tool life, improved machining stability, and superior gear accuracy. A cutting experiment verified the correctness and effectiveness of the proposed tool design method.