Journal of Manufacturing Processes 56 (2020) 1277–1285

Contents lists available at ScienceDirect

Journal of Manufacturing Processes

journal homepage: www.elsevier.com/locate/manpro

Cutting force model for power skiving of internal gear T

a, a b b
Hideaki Onozuka *, Fuminao Tayama , Yu Huang , Masatomo Inui
a
Hitachi Automotive Systems, Ltd., 4-7-1 Onna, Atsugi, Kanagawa, 243-8510, Japan
b
Ibaraki University, 4-12-1 Narisawa, Hitachi, Ibaraki, 316-8511, Japan

ARTICLE INFO ABSTRACT

Keywords: In recent years, power skiving has been rapidly promoted as a highly efficient machining method for internal
Power skiving gears. Many researches have been performed to improve the machining accuracy and tool life. In the present
Cutting study, a simulation model for the cutting area and cutting forces was developed with the aim of improving the
Force machining accuracy and tool life in the power skiving process. During the power skiving of internal gears, the
Tool
cutting direction, chip thickness, and effective rake angle have a complex relationship with the relative motion
Gear
of the tool and workpiece. First, the cutting area and uncut chip thickness during the skiving process were
analyzed by performing a simulation of the interference of a discretized cutting tool edge and workpiece surface.
Then, a two-dimensional oblique cutting model was applied to cutting edge elements. The cutting forces for the
edge elements were expressed using the cutting direction, uncut chip thickness, effective rake angle, and specific
cutting force coefficients, which represent the characteristics of the cutting forces of the workpiece material. A
method to identify the cutting force coefficients according to the effects of the change in the effective rake angle
was proposed on the basis of time-averaged cutting forces measured via cutting tests with power skiving tool
which has multiple cutting edges. An optimization method was used to minimize the error of the measured and
simulated cutting forces when the radial depth of cut and the feed rate were varied. Finally cutting tests were
performed in which the radial depth of cut was changed, and the simulated forces were compared with the
measured values. The analytical cutting forces obtained using the proposed method exhibited good agreement
with the experimental results with an error of 15 %.

1. Introduction
In recent years, power skiving process has been increasingly used
for machining internal gears. This process has the advantage that the
internal gear can be machined efficiently by a cutting tool that rotates
at a high speed in synchronization with the rotation of the workpiece.
Additionally, integrated machining from roughing to finishing can be
achieved using a multi-axis machine tool. However, because the chip
load on the cutting edge is large, the cutting forces in the skiving
process are large. Thus, it is difficult to improve the machining accu-
racy, tool life, and suppression of burrs, etc. The relative movement of
the cutting tool and workpiece surface is complex during the generation
of gear tooth in the power skiving process, and many studies have been
performed on the processing principles, machining accuracy, and tool
life for optimization of the process conditions [1–4]. Additionally,
analysis of the cutting area, chip thickness, and effective rake angle via
simulation has been proposed [5]. To predict the geometry of the cut-
ting area and machining accuracy precisely, three- dimensional com-
puter-aided design based simulations have been conducted [6–10].
The machining accuracy is affected not only by the geometry and
the motion of the cutting edge, but also the displacement of the cutting
tool and the workpiece due to the flexibility of the structure and the
cutting forces. In order to predict the cutting forces of the power skiving
process, simulation methods have been proposed [11,12]. These re-
searches enabled the prediction of cutting forces by Kienzle model using
the cutting edge geometry, depth of cut, feed rate, and cutting velocity,
etc.
In the power skiving process, the rake angle of the cutting edge is a
large negative value, and it changes significantly depending on the
position and the rotation angle of the cutting tool. For this reason, the
cutting force models with the consideration of the effects of the rake
angle have been also proposed [13,14]. In these researches, good
agreement with the measured values was obtained by introducing the
rake angle factor in cutting force coefficients. A method for identifying
the cutting force coefficients for the simulation with rake angle is also
proposed for skiving tool with a single cutting edge [15].
In the power skiving, multiple cutting edges act during the process.
Since the uncut chip thickness and effective rake angle differ for each

⁎
Corresponding author.
E-mail address: hideaki.onozuka.cf@hitachi-automotive.co.jp (H. Onozuka).

https://doi.org/10.1016/j.jmapro.2020.04.022
Received 1 December 2019; Received in revised form 27 February 2020; Accepted 11 March 2020
Available online 04 May 2020
1526-6125/ © 2020 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
H. Onozuka, et al. Journal of Manufacturing Processes 56 (2020) 1277–1285

Fig. 1. Experimental setup.

Fig. 3. Cutting area of pass 1-3.

cutting edge, it is difficult to identify the cutting force coefficients from

force acting on the cutting tool. The detected bending moment, rota-
the measured resultant cutting forces. Mathematical method to identify
tional torque, and axial force in xt-yt-zt that is the cutting tool co-
the cutting force coefficients for full immerged end milling process with
ordinate are transmitted wirelessly, and converted to machine tool
constant rake angle is proposed [[16]]. In this research, modelling of
coordinate using a personal computer (PC).
the cutting forces and identification methods of the cutting force
coefficients using simulations are proposed for actual power skiving
process with multiple cutting edges that the changes of the cutting di- 2.2. Experimental conditions
rection, chip thickness, and effective rake angle are complex. First, si-
mulations and cutting tests for skiving tool with multiple cutting edges 　In this research, cutting tests of the internal gear were performed
were performed by changing radial depth of cut and feed rate. Next, the under the following conditions: a cutting tool rotation speed of 1311.0
cutting force coefficients were optimized so that the error between the min−1, a workpiece rotation speed of 764.75 min−1, and a cutting
predicted and the measured value of the time-averaged cutting forces speed of 60 m/min. As shown in Fig. 3, the cutting process was divided
was minimized. Finally, prediction accuracy of cutting forces with into three passes. The radial depth of cut for pass 1, 2, and 3 was 1.25
proposed simulation model was evaluated via comparison with mea- mm, 0.5 mm, and 0.5 mm, respectively. The cutting tests were also
sured values. performed by varying the radial depth of cut in pass 3 from 0.3 mm to
0.7 mm and the feed rate from 0.05 mm to 0.3 mm. The experimental
conditions are presented in Table 1. Fig. 4 shows example measurement
2. Experimental configurations
results for the cutting forces in the case of continuous machining from
pass 1 to pass 3 with a tool feed rate of 0.3 mm/rev under foregoing
2.1. Experimental setup
cutting conditions. In these figures, Fx and Fz represent the cutting
forces in the radial direction and the rotation-axis direction of the
The experimental setup is shown in Fig. 1. In this research, cutting
workpiece, respectively. According to the results, the measured forces
tests were performed using a five-axis turning center. The workpiece
(particularly Fz) were significantly influenced by the noise during the
was attached to the chuck on the spindle of the five-axis turning center,
non-cutting time, and the vibration caused by the machining process
and the inside surface of the workpiece material was machined with the
also affected the measurement waveform. The cutting force generally
cutting tool inclined by 20° to the spindle. The cutting tool used in the
decreased in the following order: passes 1, 3, and 2. The radial depth of
experiment was made of high-speed steel (hardness HRC66-68) and had
cut is 0.5 mm in pass 2 and pass 3. Although the radial depth of cut is
an outer diameter of 39.848 mm, 35 teeth, and a rake angle of 20°. As
the same, measured cutting forces are larger in pass3 since the tool
shown in the figure, the shank of the power skiving tool was attached to
immersion is large [14].
the tool holder. The workpiece was made of the JIS-SCM415 material
and had outer and inner diameters of 100 and 58 mm, respectively.
Internal involute gears of module 1 with 42 teeth were machined, and 3. Simulation model
the cutting forces induced by the aforementioned power skiving tool
were measured. The cutting forces were measured using a tool holder 3.1. Simulation model
with a built-in sensor promicron SPIKE® unit. As shown in Fig. 2, it is
possible to detect the bending moment, rotational torque, and axial The simulation model is shown in Fig. 5. The cutting edges of the

Table 1
Cutting test conditions.
Machine tool 5 Axis turning center
Cutting tool Outer diameter
Number of Teeth: 35
Workpiece JIS SCM415
Outer Diameter: 100 mm
Inner Diameter: 58 mm
Number of Teeth: 60
Module: 1
Cutting Conditions Cutting Velocity
Radial depth of cut
Pass1
Pass2
Pass3
Feed rate 0.05−0.3 mm/rev
Fig. 2. Measurement of cutting forces.

1278
H. Onozuka, et al.
Fig. 4. Examples of measured cutting forces in the radial and axial direction.
Fig. 5. Simulation model of power skiving.
tool rotates clockwise with a speed of ωt around the rotation axis zt,
where φt(t) represents the angle from the x-axis at time t. The work-
piece is a ring with an inner diameter of rw, and it also rotates clockwise
with respect to the z-axis at a speed of ωw. The rotation angle of a
cutting edge from the x-axis at time t is φw(t). The tool rotation axis zt is
assumed to be inclined by an angle θ to the x-axis of the work co-
ordinate system. The center of the tool in the x-axis direction viewed
from the center of the workpiece is rx. Fig. 6 shows the outline of the
cutting edge in the tool coordinate system. The rake face is flat and
inclined to the xt axis by 20°. The analysis was performed using the
numerical calculation software Scilab.
For the contour point on the tool cutting edge in Fig. 6,
x t1 x tN
De = yt1 ytN
zt1 ztN
where [xti, yti, zti]T is the point Qi in cutting tool coordinate. The points
on the tool cutting edge contour Ce at time t are defined by Eq. (2)
according to the rotation angle about the zt axis φt(t), rotation angle
Journal of Manufacturing Processes 56 (2020) 1277–1285
Fig. 6. Geometry of the cutting edge of the power skiving tool.
about the z axis of the workpiece φw(t), displacement of the center of
the cutting tool x-axis direction rx, and tilt angle about the x-axis of the
tool rotation axis θ.
1 1
Ce (t ) = Rz ( w (t )) Rx ( ) Rzt ( t (t )) De + rx 0 0
0 0 (2)
In Eq. (2), Rx, Rzt, and Rz represent rotation matrices about the x, zt,
and z axes, respectively.
Fig. 7 shows the relative movement of the cutting tool in the case
where the workpiece is fixed. This figure describes an example of ma-
chining pass 3. The green colored area corresponds to the cutting area.
3.2. Oblique cutting model
Fig. 8 explains the analysis of the interference between the nodal
points on the work surface and the tool cutting edge during the process.
Qj,i(t) is the i-th point of j-th cutting edge contour Ce(t) at time t. Ej,i(t) is
an element of discretized cutting edge, and it is expressed as
E j,i = Qj,i+1 Qj,i . The surface of the workpiece is represented by 80 ×
50 point clouds. Pwl,k is the l-th and k-th point in axial and tangential
direction. If there is a point Pwl,k inside the 3D edge contours Ce(t) and
Ce(t-Δt) as calculated via Eq. (2), the point Pwl,k is moved to the side of
the 3D edge. As shown in the figure, a triangle containing an inter-
section point inside with a straight line through Pwl,k parallel to the x-
axis is searched for. Then, Pwl,k is moved to P'wl,k that is the intersection
of this line and the triangle Qj,i(t)Qj,i+1(t-Δt) Qj,i+1(t). The chip thick-
ness hj,i(t) for the element Ej,i(t) of the cutting edge is the length of the
perpendicular line from Pwl,k to triangle Qj,i(t)Qj,i+1(t-Δt) Qj,i+1(t). In
this research, it is approximated using the area of triangle expressed by
(1)
Fig. 7. Cutting area and locus of the cutting edge with to relative motion of tool
and workpiece in pass 3.
1279
H. Onozuka, et al. Journal of Manufacturing Processes 56 (2020) 1277–1285

Fig. 8. Collision of the cutting edge and workpiece. Fig. 10. Simulation results for the cutting area in passes 1-3.

ΔX and Ej,i ;
X × E j,i (t )
h j,i (t ) =
|E j,i (t )| (3)
where ΔX = Pwjk - P'wjk.
Next, we assume that every element of the cutting edge Ej,i(t) per-
forms two-dimensional (2D) oblique cutting. In Fig. 8, we assume that
when the Ej,i(t) proceeds in the direction of -Hj,i(t), the chip flows in the
direction of the vector Vj,i(t) perpendicular to Ej,i(t) and -Hj,i(t), in ac-
cordance with Colwell's law [[17]]. We assume that 2D oblique cutting
is performed in a plane determined by -Hj,i(t) and Vj,i(t) and that the
rake face of the power-skiving tool is flat, as shown in Fig. 6. Fig. 9
describes the oblique cutting model. Horizontal force Fhj,i and vertical
force Fvj,i act in the direction of cutting direction and chip flow direc-
tion, respectively. S’j,i(t) represents the projected normal vector of the
rake face Sj,i(t) to -Hj,i(t) Vj,i(t) plane at time t. For all the elements of
cutting edge Ej,i(t), S’j,i is expressed as follows;
Sj,i· Ej,i (t )
S' j,i (t ) = Sj,i (t ) E j,i
|Ej,i (t )|2 (4)
The angle between S’j,i(t) and –Hj,i(t) is the effective rake angle αj,i
(t).
Hj,i (t ) S ' j,i (t )
1
j,i (t ) = cos
|Hj,i (t ) S' j,i (t )| (5)
In accordance with the foregoing method, the cutting area when the
skiving tool rotates was simulated for pass 1 to pass 3. In the simulation,
the rotation angle of the skiving tool with respect to the x-axis shown in
Fig. 5 was divided into 100 steps in the range of −40° to 40° (−2π/
9 < φt(t) < 2π/9). Fig.10 shows the cutting area for pass 1 to pass 3.
The areas of green and gray stripes in the figure correspond to the
machined surface generated by the process; the color alternates be-
tween green and gray every five calculation steps. From this figure, it
can be seen that in the first process pass 1, the cutting is started from
the left side of the tooth surface, and the tool is detached from the
material. However, in the third process (pass 3), the cutting is started
from the right side and the tool is detached from the left side. The
position of the penetration and detachment of the cutting edge vary
owing to the process. In the power skiving process, when the machining
is performed in multiple pass by changing the center of the cutting tool
in radial direction, the rx in Eq. (2) is changed. When rx is changed, the
cutting edge draws a different locus depending on the value of rx. Thus,
the penetration and detachment position var according to the pass.
Fig. 11 shows the effective rake angle at the point on the cutting
edge in passes 1–3. The broken line in the figure indicates the change in
the effective rake angle due to tool rotation at the four points Q5, Q10,
Q15, and Q20 on the cutting edge. The thick line indicates the portion
where the cutting edge removes workpiece material. The figure sug-
gests the following;
1) In pass 1 and 2, the effective rake angles are generally negative on
the left side of the cutting edge (points Q5 and Q10) and positive on
the right side (Q15 and Q20). In pass 3, the effective rake angles are
generally negative at all four points in the rotation angle range of 0
to −0.4 rad during the cutting.
2) In pass 1, the left-side point Q10 is predominantly involved in the
cutting. Q5 and Q20, which are at the center of the cutting edge, are
not involved in the cutting. The right-side point Q15 is involved in
slight cutting at a rotation angle of −0.3 rad.
3) In passes 2 and 3, the left center (Q5) and right cutting edge (Q15
Q20) are also involved in the cutting. Additionally, the differences in
the effective rake angles at the different positions on the cutting
edge are smaller than those for pass 1.

Fig. 12 represents the chip thickness for Fig. 11. As shown in pass 1,
the left-side point Q10 is mainly involved in the cutting, whereas in pass
2 and 3, the uncut chip thickness is identical among the four points.

3.3. Cutting force model

As indicated above, it was possible to calculate the effective rake

angle and uncut chip thickness associated with the tool rotation for
each discretized element of the cutting edge of the skiving tool. Next,
cutting force on each cutting edge element was analyzed using the
aforementioned 2D oblique cutting model. We assumed that the hor-
izontal component of the force Fhj,i(t) is applied in the direction op-
posite to the cutting direction and that Fvj,i(t) is applied to the cutting
edge element Ej,i(t) in the chip flow direction, as shown in Fig. 9. These
forces are expressed by the following equations.

Fig. 9. Oblique cutting model. Fhj,i (t ) = gj,i (t )(Khc (1 K j,i (t )) h j,i (t ) + Khe )|E j,i (t )| Hj,i (t ) (6)

1280
H. Onozuka, et al. Journal of Manufacturing Processes 56 (2020) 1277–1285

Fig. 11. Simulation results for the cutting area in passes 1-3.

Fvj,i (t ) = gj,i (t )(K vc h j,i (t ) + Kve )|E j,i (t )| Vj,i (t ) (7) 3.4. Identification of specific cutting force coefficients

Here, Khc, Khe, Kvc, Kve, and Kα represent the specific cutting force The cutting force model of power skiving is described above. A
coefficients. Hj,i(t) represents the cutting speed, Vj,i(t) represents the method for identifying the constants (specific cutting force coefficients)
unit vector perpendicular to Hj,i(t) and Ej,i(t), and αj,i(t) represents the Khc, Khe, Kvc, Kve, and Kα which represent the characteristics of the
effective rake angle. gj,i(t) is a unit step function. When the cutting edge cutting force in Eqs. (8)–(10) was investigated. In this study, the spe-
is in the cutting area, gj,i(t) = 1. In Eq. (6), the magnitude of the hor- cific cutting force coefficients were identified with consideration of the
izontal component of the force Fhj,i(t) increases proportionally to the effects of the change in the effective rake angle by using measured time-
uncut chip thickness hj,i(t) and the length of the cutter element |Ej,i(t)|. averaged cutting forces [[16]].
Additionally, it decreases with an increase in the effective rake angle. Time averaged cutting forces for cutting tool that has multiple
As indicated by Eq. (7), the vertical component of the force Fvj,i(t) in- cutting edges are expressed as following equations using Eqs. (8) and
creases in proportion to the uncut chip thickness hj,i(t) and the length of (9).
the cutter element.
Then, cutting forces for all of the N elements and all of the M cutting F¯h = Khc
1 T M N
gj,i (t ) (1 K j,i (t )) h j,i (t ) |E j,i|
edges of the power skiving tool (given by Eqs. (6) and (7)) were in- T t=0 j =1 i=1

tegrated. The cutting forces acting on the entire cutting tool were given 1 T M N
Hj,i (t )dt + Khe gj,i (t ) |E j,i| Hj,i (t ) dt
by the following equations. T t=0 j=1 i=1
= Ah Khc + Bh Khc (11)
M N
Fh (t ) = gj,i (t ) (Khc (1 K j,i (t )) h j,i (t ) + Khe )|E j,i (t )| Hj,i (t )
j=1 i=1
1 T M N
(8) F¯v = Kvc gj,i (t ) h j,i (t )|Ej,i (t )| Vj,i (t )dt
T t = 0 j=1 i=1
1 T M N
M N + K ve gj,i (t ) |E j,i| Vj,i (t ) dt
Fv (t ) = gj,i (t )(Kvc h j,i (t ) + K ve )|E j,i (t )| Vj,i (t ) T t=0 j=1 i=1
j =1 i=1 (9)
= Av K vc + B v K vc (12)

Fx (t ) where,
F (t ) = Fy (t ) = Fh (t ) + Fv (t )
Fz (t ) (10)

Fig. 12. Simulation results of uncut chip thickness in pass 1-3 with feed rate 0.3 mm/tooth.

1281
H. Onozuka, et al. Journal of Manufacturing Processes 56 (2020) 1277–1285

workpiece when the feed rate is low.

In this research, cutting force model and identification method are
proposed focusing on radial cutting force and axial cutting force i.e., the
x-directional force and the z-directional force, respectively. In parti-
cular, the radial cutting force significantly affects the machining accu-
racy owing to the elastic deformation of the cutting tool during the
process. Regarding to the x- and z-directional force components, Eqs.
(10)–(12) are expressed as follows:

dAhx dAvx
F¯x df df Khc Bhx B vx Khe
F = = f+
F¯z dAhz dAvz Kvc Bhz B vz K ve
df df (15)

In contrast, if we assume that the average value of the cutting forces

measured in the cutting tests with changing the feed rate is expressed
by the following equation;

F¯ x x
F¯m = mx = f+
¯
Fmz ¯z ¯
z (16)

The cutting force coefficients are given by Eqs. (15) and (16);
1
dAhx dAvx
Khc df df x
=
K vc dAhz dAvz ¯z
df df
1
Khe Bhx B vx x
=
K ve Bhz B vz z (17)
Fig. 13. Simulation results for the identification of the cutting force coeffi-
cients. The effective rake angle for each cutting edge element varies ac-
cording to the pass, as shown in Fig. 11. Because the measured cutting
Ahx forces are affected by the effective rake angle, the cutting force coef-
1 T M N
ficients Khc, Khe, Kvc, and Kve in pass 1–3 can be evaluated using Eq.
Ah = Ahy = gj,i (t ) (1 K j,i (t )) h j,i (t )
T t=0 j =1 i=1
(17) if Kα is provided. Therefore, the value of Kα that minimizes the
Ahz
error between the measured cutting forces and the forces predicted
|E j,i| Hj,i (t )dt
using the identified cutting force coefficients is determined. The process
Bhx is described as follows:
1 T M N
Bh = Bhy = gj,i (t ) |E j,i| Hj,i (t ) dt
T t=0 j =1 i=1
Bhz (13) 1) Determine the relationship between the feed rate and the time
averaged cutting force from the measurement.
Avx 2) Assume a factor Kα that indicates the effects of the rake angle on the
1 T M N
Av = Avy = gj,i (t ) h j,i (t )|Ej,i (t )| Vj,i (t )dt cutting force.
T t=0 j=1 i=1
Avz 3) Calculate Ah, Bh, Av, and Bv via simulation with a varying feed rate
in pass 3.
B vx
1 T M N 4) Calculate the cutting force coefficients Khc, Khe, Kvc, and Kve using
Bv = B vy = gj,i (t ) |Ej,i| Vj,i (t ) dt
T t=0 j=1 i=1 the results of 1) and 3).
B vz (14) 5) Simulate passes 1–3 using the cutting force coefficient obtained in 4)
In Eqs. (13) and (14), Ah, Bh, Av, and Bv can be determined via to determine the time-averaged cutting force.
simulation if the cutting edge geometry, cutting conditions, and Kα 6) Calculate the error between the measured and analyzed values of
(which indicates the effect of the rake angle on the cutting forces) are the time-averaged cutting force in passes 1–3.
provided. 7) Determine whether the error is the minimized for the selected Kα
Fig. 13 shows the relationship between the feed rate f (mm/rev) and value.
the x- and z-directional components of Ah, Bh, Av, and Bv when the
simulation is performed under the following conditions: Kα = 6.0 and a The identification process is presented in Fig. 14.
tool feed rate varying from 0.05 mm/rev to 0.3 mm/rev in pass 3.
According to the results, Ah and Av are almost proportional to the feed 4. Cutting force coefficients in cutting tests
rate f given by Eqs. (13) and (14), as they are affected by the uncut chip
thickness hj,i. Although Bh and Bv are slightly influenced by the feed 4.1. Cutting tests
rate f, they are assumed to be almost constant. As shown in the figure,
Bh and Bv are approximated by the average value even if the conditions Fig. 15 shows the measured results for the time-averaged cutting
are changed. According to Eqs. (13) and (14), Bh and Bv are not initially forces when the feed rate was changed from 0.05 mm/rev to 0.3 mm/
affected by changes in the uncut chip thickness hj,i due to changes in the rev in pass 3. The time-averaged cutting forces increased approximately
feed rate. However, because the workpiece is expressed by a finite point linearly with an increase in the tool feed rate. Thus, they were ap-
cloud in the simulation, the distance of the points affects the error of proximated as shown in the figure.
determination for the interference of the cutting edge and the According to the results in Fig.15,

1282
H. Onozuka, et al. Journal of Manufacturing Processes 56 (2020) 1277–1285

Fig. 16. Simulated time-averaged cutting forces with respect to the coefficient
for the effective rake angle (Kα) in pass 1-3.

Fig. 14. Process of identification of the cutting force coefficients.

Fig. 17. Optimization of the cutting force coefficients.

3 ¯ ¯ ¯ ¯
Fig. 15. Measured time averaged cutting forces by changing the feed rate in
RSS= {(Fxmi Fxai )2 + (Fzmi Fzai )2} (20)
i=1
pass 3.
Fig. 17 shows the RSS for Fig. 16. According to these results, Kα =
5.6 (1/rad) was used Kα with the minimum RSS. From this result,
x
=
828.15
, x
=
51.954 cutting force coefficients are identified as Khc = 931 (N/mm2), Khe, =
z 2195.3 z
106.41 (18) 21.2 (N/mm), Kvc, = 2871 (N/mm2), and Kve = 19.7 (N/mm).

In contrast, assuming Kα = 6.0 in Fig. 13, the simulation results

indicate the following: 4.3. Validation of analytical results

dAhx dAvx Fig. 18 shows the analytical results for the cutting forces in x and z
df df 0.4112 0.4551 direction with a feed rate of 0.3 mm/rev in pass 3. The waveform of the
=
dAhz dAvz 1.6791 0.1081 cutting forces varies with a period of approximately 0.18 rad, which
df df corresponds to the cutting interval of the cutting tool with 35 teeth.
Bhx B vx 1.4172 3.5477
=
Bhz B vz 7.4993 0.6643 (19)

Therefore, according to Eq. (17), the cutting force coefficients are

Khc = 1173.6 (N/mm2), Khe, = 12.460 (N/mm), Kvc = 2872.8 (N/
mm2), and Kve = 19.621 (N/mm).

4.2. Optimization of cutting force coefficients

The error between the measured and analyzed time-averaged cut-

ting forces was evaluated using the process shown in Fig. 14. Fig. 16
shows the measured and simulated time-averaged cutting forces for
passes 1–3 with respect to Kα. The errors were calculated using the
residual sum of squares (RSS). The RSS is expressed by the following
equation, where the measured cutting force in pass i (i = 1, 2, 3) is Fig. 18. Simulated cutting forces in radial and axial directions with multiple
¯ ¯ ¯ ¯
given by Fxmi and Fzmi and the simulated values are Fxai and Fzai : cutting teeth in pass 3.

1283
H. Onozuka, et al.
Fig. 19. Measured cutting forces in radial and axial direction with multiple
cutting teeth in pass 3.
Fig. 19 shows the waveform of the cutting force measured at the feed
rate of 0.3 mm/rev in pass 3. The horizontal axis of the graph represents
time. A comparison of Figs. 18 and 19 reveals the following.
1) The measured results in Fig. 19 exhibit no variation in the cycle time
per cutting edge but fluctuate within the cycle time of 0.045 s,
which corresponds to one revolution of the cutting tool.
2) In Figs. 18 and 19, the average values for Fx and Fz are almost
identical. The amplitude of the cutting force variation is similar for
Fx, but Fz varies by approximately three times the amplitude of the
analytical results.
As a major factor in the difference in the amplitude of the cutting
force, following was assumed;
1) As shown in Fig. 4, electrical noise with an amplitude of approxi-
mately 200 N was observed on one side even when this side was not
processed.
2) The vibration of the tools and workpiece during the machining.
3) Aliasing due to an insufficient resolution in the analysis.
4) Changes in the cutting force induced by the cutting edge due to run
out of the tool.
Fig. 20 indicates the comparison of the measured and analyzed time
averaged cutting forces when the feed was changed from 0.05 mm to
0.3 mm in pass 3. Measured forces in this figure are values those were
included in the identification process of cutting force coefficients. The
maximum error is 15 %.
Finally, the analyzed cutting forces were validated using measured
results that were not used to identiy the cutting force coefficients. Here,
the cutting force was measured by varying the radial depth of cut in pass
3 and compared with the analyzed values. Fig. 21 presents the cutting
Fig. 20. Validation of simulated average cutting forces with measured forces
for different feed rate in pass 3.
1284
Journal of Manufacturing Processes 56 (2020) 1277–1285
Fig. 21. Cutting area for different values of the radial depth of cut.
Fig. 22. Validation of simulated average cutting forces with measured forces
with respect to radial depth of cut in pass 3.
area when the radial depth of cut is changed as 0.3, 0.5, and 0.7 mm in
pass 3. As the radial depth of cut increases, the cutting area also increases
in the radial direction (x direction) and the rotational axis direction (z
direction). Fig. 22 presents a comparison of the time-averaged cutting
forces in Fig. 20. As shown, the results of the analysis and the experiment
agree well, with a maximum error of approximately 13 %.
5. Conclusions
To improve the efficiency, accuracy, and tool life of the machining
process for internal gears, an analytical model for power skiving process
was investigated. In this research, a simulation method is proposed based
on interference of discretized cutting edge elements and point clouds of
workpiece surface. Cutting forces are modelled with consideration of the
effects of the change of effective rake angle during the process. In ad-
dition, the identification method of cutting force coefficients with skiving
tool that has multiple cutting edges were also proposed. Analytical re-
sults were validated by cutting tests. The results are as follows;
(1) An analytical model of cutting forces that considers the effects of
the changes in the effective rake angle during the cutting process
was proposed.
(2) Cutting force coefficients with the consideration of change of ef-
fective rake angle were identified using measured cutting forces by
changing feed rate in pass 3, and optimized in order to minimize the
error between measured and analysed time averaged cutting forces.
(3) The analytical results for the cutting forces by proposed method in
this research were validated using cutting test results. The error of
the time-averaged cutting forces when the feed rate is varied in pass
3 was 15 %. In addition, the radial depth of cut is changed in pass 3
under the condition that is not used for identifying the cutting force
coefficients, and the analyzed forces were validated. The results
agreed well with an error of approximately 13 %.
H. Onozuka, et al.
References
[1] Jaster Matther. Skiving: a manufacturing renaissance. Gear Technol 2017. August.
[2] Monden Tetsuji, Kikuchi Toshimasa, Chihara Yu, Nakamura Yozo. MHI super-
skiving system for longer tool life and enhanced efficiency in internal gear cutting.
Mitsubishi Heavy Ind Tech Rev 2015;52(1).
[3] Moriwaki I, Nakamura M, Hasegawa T, Funamoto M, Uriu K, Murakami T,
Tachikawa T, Nagata E, Kurita N, Kobayashi Y. Tooth geometry design of cylindrical
skiving cutter for internal gears. VDI-Berichte Nr 2013;2199(1):329–40.
[4] Stadtfeld HJ. Power skiving of cylindrical gears on different machine platforms.
Gear Technol 2014:52–62.
[5] Fritz Klocke, Christian Brecher, Lopenhaus Christoph, Philipp Ganser, Julian
Stautdt, Krömer Markus, et al. Technological and simulative analysis of power
skiving. Procedia CIRP 2016;50:773–8. 26th CIRP Design Conference.
[6] Tapoglou Nikolaos. Calculation of non-deformed chip and gear geometry in power
skiving using a CAD-based simulation. Int J Adv Manuf Technol 2018;9.
[7] Lei Xu, Qicheng Lao, Zhiyi Shang. Calculation of skiving cutter blade. In:
Fangeditor. 6th International Conference on Computer-Aided Design,
Manufacturing, Modeling and Simulation (CDMMS 2018). A; 2018.
[8] Spath D, Huehsam A. Skiving for high-performance machining of periodic structure.
CIRP Ann Manuf Technol 2002;51(1):91–4.
[9] Guo E, Hong R, Huang X, Fang C. Research on the cutting mechanism of cylindrical
1285
Journal of Manufacturing Processes 56 (2020) 1277–1285
gear power skiving. Int J Adv Manuf Technol 2015;79:541–50.
[10] Guo E, Hong R, Huang X, Fang C. Research on the design of skiving tool for ma-
chining involute gear. J Mech Sci Technol 2014;28(12):5107–15.
[11] Antoniadis Aristomenis. Gear skiving –CAD simulation approach. Comput Des
2012;44:611–6.
[12] Aristomenis Antoniadis, Nectarios Vidakis, Bilalis N. A simulation model of gear
skiving. J Mater Process Technol 2004;146:213–20.
[13] Vargas Bruno, Zapf Matthias, Klose Jan, Zanger Frederik, Schulze Volker.
Numerical model of cutting forces in gear skiving. 17th CIRP Conference on
Modelling of Machining Operations, 82. 2019. p. 455–60.
[14] McCloskey Pierce, Katz Andrew, Berglind Luke, Erkorkmaz Kaan, Ozturk Erdem,
Ismail Fathy. Chip geometry and cutting forces in gear power skiving. CIRP Ann
Manuf Technol 2019;68:109–12.
[15] Kobayashi Go, Ren Zongwei, Fang Zhenglong, Sugita Naohiko, Nishikawa Tsukasa,
Shimada Satoshi, et al. Analysis of cutting forces of power skiving based on oblique
cutting model (in Japanese). In: The Japan Society for Precision Engineeringeditor.
Proceedings of JSPE Semestrial Meeting 2019 JSPE Spring Conference. The Japan
Society for Precision Engineering; 2019.
[16] Altintas Yusuf. Manufacturing automation, metal cutting mechanics, machine tool
vibrations, and CNC design. Cambridge University Press; 2000. p. 45.
[17] Colwell LV. Predicting the angle of chip flow for single-point cutting tools. Trans
ASME 1954;76:199–204.