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Power skiving is the most modern gear manufacturing process, which is widely applied in recent years, ensuring higher productivity. It is a continuous manufacturing process which involves gear and tool meshing, able to produce internal and external gears at a much faster rate than shaping and hobbing. The main functionality of the power skiving simulation software includes the calculation of a gear gap and the undeformed chip geometry as well as the cutting forces produced during the process.

The Gear Skiving kinematics consist of three different motions. The rotary motion of the cutter and the workpiece as well as the axial feed of the cutter along the direction of the gear gap.

Τhe chip geometry of each cutting pass is identical for every cutting tooth, considering a stable depth of cut. However the chip geometry greatly differs between internal and external gears and it is modified depending on the axial feed of the manufacturing process. In specific, for a same module and cross axis angle, internal gear cutting chips are generally longer than those of external gears. In addition, raising the axial feed of the simulation chips with increased thickness are produced and by increasing the Cross Axis angle of the cutting tool, the chip is generally lengthened. The simulation model is able to predict the undeformed 3D chip geometry along with its thickness and total area.

The undeformed chip geometry is used in cutting force prediction.

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