Skiving method for chamfering and deburring of cylindrical gears using two disk tools

Gear chamfering and deburring are widely employed in manufacturing to remove burrs or smooth sharp edges from gear parts using a specialized tool, which minimizes the stress concentration on the tooth surface. In recent years, gear chamfering and deburring have become indispensable processes in high-performance gear manufacturing for new-energy vehicles and industrial robots. This study presents a novel skiving method for chamfering and deburring cylindrical gears based on tooth profile generation using a cutting tool edge. A mathematical model is proposed to calculate the cutting edges of a chamfering tool for skiving gear tooth profiles. By developing an evaluation method for chamfering results, various concerns regarding gear skiving chamfers are discussed, including the description of the evaluation method, impact of tool parameters on chamfering results, analysis of the flank interference of the tool, and versatility of chamfering tools when machining different gears. An experimental skiving chamfer is designed on a specialized machine using two high-speed steel chamfering tools with an AlCrN Pro coating. The obtained results demonstrate deviations between the theoretical and measured values <13 %, confirming the validity of the proposed approach. These findings offer theoretical support for optimizing cylindrical gear chamfering processes and guidance for designing skiving chamfer tools.