Design and cutting performance analysis of cylindrical gear skiving tool with uniform working rake angle

Gear skiving is an efficient and precise method for gear manufacturing. Traditional conical skiving tools feature a structural relief angle on the flank and a plane rake face, which often leads to inconsistent accuracy after regrinding and an unreasonable working rake angle. This paper proposes a novel design method for cylindrical gear skiving tool with uniform working rake angle based on origin offset. A motion model for offset gear skiving is established, and the conjugate contact relationship between the tool and the workpiece is derived. The cutting tool is constructed by a free-form rake face and a helical flank face. The working rake angle is controlled to be uniform, and the flank face is confirmed to have no interference through sweeping trajectory calculation. A multi-physics coupling simulation model for cutting forces and temperature field is developed using finite element method. The results demonstrate that, compared to the conventional plane-rake-face tool, the proposed tool with a curved-rake-face significantly reduces cutting force fluctuations and peak temperature, leading to enhanced tool life, improved machining stability, and superior gear accuracy. A cutting experiment verified the correctness and effectiveness of the proposed tool design method.