Abstract In gear skiving, tool wear is one of the primary issues owing to the large thermomechanical cutting load. However, the effective rake angle and depth-of-cut can vary continuously throughout a single cut, leading to a complex uncut chip geometry that significantly hinders the understanding of the cutting characteristics and adds further difficulty to the prediction of tool wear. This study proposes a parametric modeling method for calculating the uncut chip geometry for each cutting pass. Developments in the rake angle and depth-of-cut (as subjected to an uncut chip) were comprehensively investigated with an aim to advance the understanding of the cutting characteristics during a single cut. Based on the uncut chip geometry, the crater wear was successfully predicted using the derived stress and temperature data, followed by a single-tooth skiving wear test verification. By comparing numerical and experimental results for crater wear, an error of less than 5% was obtained in both depth and area. The proposed method provides a non-CAD/CAM-engine-software/environment-based alternative for calculating the process of an uncut chip, clearly advancing the flexibility in cutting parameter optimization and cutter design.

中文翻译：

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未切削切屑几何形状的参数化建模，用于预测齿轮刮削中的凹坑磨损

摘要 在滚齿加工中，由于热机械切削载荷大，刀具磨损是主要问题之一。然而，有效前角和切削深度可以在整个单次切削中连续变化，导致复杂的未切削切屑几何形状，这大大阻碍了对切削特性的理解，并进一步增加了刀具磨损预测的难度。本研究提出了一种参数化建模方法，用于计算每次切削走刀的未切削切屑几何形状。对前角和切削深度（受到未切削切屑的影响）的发展进行了全面研究，目的是加深对单次切削过程中切削特性的理解。基于未切削的切屑几何形状，使用衍生的应力和温度数据成功预测了凹坑磨损，随后进行单齿刮削磨损试验验证。通过比较陨石坑磨损的数值和实验结果，在深度和面积上都获得了小于 5% 的误差。所提出的方法为计算未切割芯片的过程提供了一种非 CAD/CAM 引擎软件/环境的替代方案，明显提高了切割参数优化和刀具设计的灵活性。