Abstract:  Aiming at the problem that it was time-consuming and complicated to calculate the cutting force in NC power skiving machining by modeling and finite element simulation, a cutting force prediction method based on dexel discrete geometric modeling was proposed. Firstly, the kinematic model of power skiving was constructed and applied to solid modeling based on dexel. Then, the three-dimensional undeformed chip shape was extracted, and the two-dimensional chip cross section was obtained by DILLONI triangulation. The effective rake angle and inclination angle were determined by calculating the cutting speed on the discretized cutting edge, and the cutting force was predicted by using the bevel cutting model. In addition, the cutting force of the whole process was estimated by modeling and superimposing of partial workpiece, so as to improve the simulation efficiency. Finally,  the prediction method was verified on NT5400DCG turning and milling machine. The research results show that, compared with the existing methods, the calculation efficiency and prediction accuracy of the proposed method are improved, the root mean square error of cutting force prediction is reduced by about 7N, and the accuracy is improved by about 9.7%, which is beneficial to preventing the early fatigue damage of the cutting edge, thus laying a good foundation for the highquality and strong scraping processing of the cylindrical gear.

Key words:  gear processing; power skiving; cutting force prediction; dexel data; computational efficiency

PENG Gui-zhi, LI Guo-qing. Efficient cutting force prediction method in cylindrical gear scraping machining［J］.Journal of Mechanical & Electrical Engineering, 2021,38(8):1058-1063.