# The Simulation Analysis of Cutting Characteristics and Chip Formation Mechanism in Gear Skiving
## 6 Conclusions  
Through simulation methods, the variation patterns of cutting thickness, tool working angles, cutting speed, and cutting stress during the gear skiving process were analyzed, revealing the characteristics of the skiving cutting process.  
1. **Kinematic Simulation Analysis:** The kinematic simulation analysis of gear skiving revealed the variation pattern of the cutting thickness along the tool edges and the skiving cutting profile. It was found that the recessing edge and top edge remove a larger amount of material, leading to uneven wear on the skiving tool edges.
2. **Numerical Simulation Calculations:** The numerical simulation method of the gear skiving process was provided, which can be used in the cutting parameter optimization of gear skiving. The numerical simulation calculations indicate that the cutting conditions and chip evacuation state are poorest when the skiving tool exits the gear slot, making the tool more prone to wear and affecting the quality of the workpiece.
3. **Finite Element Simulation Analysis:** A new method of the FEA simulation of gear skiving was provided, and the chip formation mechanism in gear skiving was investigated. The finite element simulation analysis shows that the maximum cutting stress occurs at the chip convergence area at the intersection of the approaching edge and top edge. Fractures of chips are prone to being formed in this region, causing fluctuations of cutting force, which negatively impacts tool life and the quality of the tooth surface.  
Figure 11: Photos of skiving tool tooth wear and chips.  
**Author Contributions:** General concept and original draft preparation, R.M.; Kinematic simulation analysis of gear skiving, P.T.; Finite element simulation analysis of gear skiving, L.W.; Reviewing and editing, Y.Z.; Numerical simulation calculations of gear skiving, Z.G.; Preparation of conclusions and editing, S.M. All authors have read and agreed to the published version of the manuscript.  
**Funding:** This research was supported by the National Basic Product Innovation Research Program of China (DEDP2023036).  
**Institutional Review Board Statement:** Not applicable.  
**Informed Consent Statement:** Not applicable.  
**Data Availability Statement:** The original contributions presented in this study are included in the article. Further inquiries can be directed to the corresponding author(s).  
**Conflicts of Interest:** The authors declare no conflicts of interest.  
**Nomenclatures**  
\(S_{c}(X_{c},Y_{c},Z_{c})\) coordinate systems of the skiving tool  
\(S_{w}(X_{w},Y_{w},Z_{w})\) coordinate systems of the workpiece  
\(\Sigma\) crossed axes angle  
\(a\) center distance  
\(L\) offset distance  
\(A\) approaching cutting edge  
\(R\) recessessing cutting edge  
\(T\) top cutting edge  
\(\omega_{w}\) angular velocity of workpiece  
\(\omega_{c}\) angular velocity of tool  
\(f\) feed velocity of workpiece  
\(Z_{w}\) number of teeth of workpiece  
\(Zc\) number of teeth of tool  
\(p_{z}\) helix lead of workpiece  
\(n\) normal vector of cutting plane  
\(v\) sliding velocity of tool relative to workpiece  
\(v_{n}\) unit vector of normal cutting velocity  
\(P_{0}\) orthogonal plane  
\(\gamma_{n}\) rake angle  
\(n\) normal vector of cutting plane  
\(n_{r}\) normal vector of rake face  
\(n_{f}\) normal vector of flank face  
\(t_{r}\) helix vector of flank face  
\(\alpha_{n}\) clearance angle  
\(\lambda_{s}\) inclination angle  
\(v_{t}\) tangential cutting velocity  
\(\psi\) cutting edge unfolding angle  
\(\varphi_{c}\) cutter rotation angle  
\(\sigma_{\max}\) maximum equivalent stress  
\(\sigma\) equivalent stress