The approach developed in this research aims to aid a further understanding of the correlations between the energy generated during material removal and the power signals from the machine control during generating gear grinding.

Gear skiving is used for both soft and hard finishing. As a quality critical final step in hard finishing, the process can be used to create modifications to the tooth flank. At present there is no knowledge of the extent to which topological modifications can be applied by gear skiving. In this report, the feasibility of manufacturing topological modifications on an external gear through adapted kinematics for gear skiving has been investigated.

As the challenges in bevel and hypoid gear manufacturing need to be addressed, the objective of this paper is to show the tool and process design can be optimized based on the results of the manufacturing simulation BevelCut.

For the research developed in this work, an existing simulation model of the generating gear grinding process based on a penetration calculation approach is used. Further, an extension of the model considering a realistic modeling of the grinding worm topography and the macro movements of the grinding worm during the process is presented. The result of the simulation is the microinteraction characteristics throughout
the grinding of the gear flank. In the end, the information about microinteraction characteristics obtained will be used for the calculation of force and energy in generating gear grinding.

Due to near-net shape production, additive-manufactured (AM) gears have a high potential to decrease costs and increase resource efficiency. The decreasing product life cycles as well as the increasing individualization of components demand high flexibility in manufacturing processes