CAD-Based Simulation Model for the Calculation of Chip Geometry and Cutting Force Components in Gear Shaping

Involute gears are a vital component used in industry due to their ability to provide flexible and accurate rotary motion. Gear shaping is one of the most prominent gear cutting processes as it can be used to effectively manufacture spur and helical external as well as internal gears. Thus, the accurate prediction of the cutting forces developed during the cutting process is of great importance because it can greatly affect the wear and the cutting tool’s life. In this work, a simulation model was developed based on a commercial CAD software, able to simulate the kinematics involved in the process and provide accurate results regarding the undeformed chip geometry as well as the cutting forces. In order to verify the accuracy of the model, the produced gear flanks are compared with the theoretical ones and the calculated cutting forces are compared with the respective measured forces obtained from the literature.