Dr.-Ing. Thomas Glaser studied mechanical engineering B.Eng. and product development and manufacturing M.Eng. at the University of Applied Sciences in Aalen. During his master's degree, he worked as a research assistant at the Institute of Drive Technology in Aalen, focusing on the series development of bevel gearboxes. He obtained his Ph.D. degree in mechanical engineering focusing on the 5-axis machining of bevel gears in cooperation between Aalen University and the Technical University of Dresden. Since 2018, he has worked for J.M. Voith SE & Co. KG | Group Division Turbo as an operating engineer with a focus on gear technology. In addition, he is a leading member of the CoC Gear Production of Voith Turbo.
This report uses an application case to demonstrate the optimization potential of gear skiving in the production of internal splines on a universal machining center. The process established in the example is then analyzed using the software tool OpenSkiving developed by the wbk Institute of Production Science of the Karlsruhe Institute of Technology (KIT) and the results are discussed. Finally, the most important findings are summarized.
Bevel gears are widely used in various industrial applications, such as automotive, aerospace, and marine industries, due to their ability to transfer power between non-parallel shafts. The conventional manufacturing of bevel gears involves several time-consuming and costly processes, including gear blank preparation, gear cutting, and gear finishing. The increasing demands on gear components regarding increasing power density, reducing installation space, reducing weight, and increasing efficiency are also reflected in the design of gear components. The reduction of installation space and weight as well as the increase in power density often leads to an optimized wheel body design that interacts with the gearing in terms of load capacity and stiffness. This leads to an increase in the required geometric degrees of freedom (DOFs). Due to the resulting complex wheel body shapes and different production-related effects, production-related geometry adjustments may also be necessary. Tools for evaluating the gearing in combination with the wheel body shape and its influences nowadays form the basis for unlocking the holistic optimization potential of transmission components.