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:: 13 September 2011 :: KLINGELNBERG POWER SKIVING INNOVATION

The entire process is highly energy-efficient, productive and flexible. In addition to the free design of the tool, tooth flank modifications can also be applied by superimposing additional movements during the skiving process. These advantages in comparison to gear hobbing, gear shaping or broaching are of particular importance for the production of internal gears. A simple comparison of shaping and skiving productivity shows that skiving is up to ten times quicker and offers a significantly longer tool life.

The newly developed Klingelnberg software illustrates the exact chipping conditions and therefore allows for a targeted optimization of the cutting geometry and the production movement.
The new stick blade tool system uses carbide technology which has long been used for production of bevel gears. "Skiving itself is in fact an ancient concept. The key innovation hereby lies in the use of stick blades and the resulting design possibilities for the cutting edge – a breakthrough in cutting technology", says Dr. Hartmuth Müller, CTO of Klingelnberg. The stick blade has the distinct advantage of offering optimal cutting geometry through grinding. This is a necessary condition for the optimization of the chip formation process and therefore forms the basis for the breakthrough of skiving.

A stick blade tool system also offers a wide range of further advantages:

• Flexibility: Using the recognised Oerlikon stick blade grinding machine, the user can cost effectively produce the tool for their own application within the shortest lead time. This process has been used and approved worldwide.
• Optimized cutting geometry: It guarantees long tool life, which is considerably longer than those of a shaping cutter or a skiving tool.
• Minimal use of carbide metal: In a stick blade tool, carbide is only used for the cutter which therefore ensures a highly efficient use of resources.

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Despite high productivity and system-inherent accuracy, the breakthrough of skiving has been denied due to the the tool problems. The chip formation process in skiving is extremely complex whereby large negative rake angles and only very small clearance angles arise during the process. The current tools, mostly cylindrical or conical solid carbide cutting wheels, have no degree of freedom for the necessary optimization. In addition to high machining forces, negative cutting angles also consistently lead to excessive wear of the tools meaning that the tool costs per component largely surpass the proportional machine costs.