Algebraic modeling of cylindrical interference-free power-skiving tool for involute internal gear cutting with tilt angle

The development of feasible methods for the design of power-skiving tools without cutting interference is essential in ensuring the accuracy of involute internal machined gears. One of the most crucial points in obtaining interference-free and re-sharpenable power-skiving tools is that of determining the cutting edge and clearance surface. The present study introduces a tilt angle during the power-skiving process to design a simple cylindrical interference-free tool shape, in which the shape of the cutting edge remains unchanged after re-sharpening. The relative position between the new tool center point and gear during machining is similarly unchanged after the re-sharpening process. In addition, the clearance angle between the tool and the gear can be easily adjusted simply by changing the tilt angle of the tool during power-skiving. The validity of the proposed design method is demonstrated through a simple numerical example. The simulation results confirm the feasibility of the proposed method.