Research

According to the current state of research, the use of multi-cutting strategies is unavoidable in Power Skiving. The reason for this is the tendency towards strongly negative rake angles with increasing depth of cut.

Due to the considerable number of cuts, the number of degrees of freedom in the process design also increases - however, a uniform calculation model is lacking. In a current research project, this gap is to be closed.

To this end, basic tests are being carried out on the influences of the most important productivity-determining design parameters of cutting depth / number of cuts and feed rate.

Based on the results, a model for tool load and chip formation is to be developed, which should make a more precise design of multi-cutting strategies possible in the future.

In Power Skiving, there are widely varying process angles and also very different meshing conditions in each cut.

Calculation models show that almost in every process locally negative effective clearance angles occur at certain cutting edge points. This is particularly critical for the cutting material carbide, which has a very high temperature resistance but is very sensitive to incorrect loads.

In a current research project, the processes at the cutting edge are being investigated in detail. Here, the cutting edge is considered as a complex three-dimensional region rather than an edge. The function of the fillet radius and in particular also the asymmetric design of the edge preparation are being investigated both simulatively and experimentally, and design guidelines are being derived from this.

Electrically driven axles have made their way into drive technology not only since the expansion of electromobility. It is not uncommon for planetary gears to be used for power transmission, the most tricky component of which from a manufacturing perspective is the ring gear. Due to a lack of alternatives, soft machining by shaping or broaching was not followed by further mechanical machining until now.

With the introduction of Power Skiving into these process chains and the simultaneous increase in geometric requirements, the question arises: What follows after heat treatment? Up to now, the process stages of Power Skiving, heat treatment and fine machining - for example by internal gear honing - have not been efficiently coordinated.

The project is investigating the optimum and optimized combination of the processes used.