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This paper presents a tri-dexel geometric engine integrated simulation model for the gear hobbing operation. The process kinematics are modeled and validated using CNC signals from a Liebherr LC500 hobbing machine. Workpiece geometry updating and cutter-workpiece engagement (CWE) calculations are efficiently realized in the tri-dexel engine. 3D force contributions at discretized nodes along the hob's cutting edges are computed considering the localized principal cutting directions, and rake and inclination angles. To measure cutting forces, a rotary dynamometer is successfully adapted and used alongside a Kalman filter to compensate for structural dynamics. The predicted forces agree well with their experimental counterparts.

This paper describes a new virtual model for predicting the uncut chip geometry and cutting forces in power skiving, which is a high-speed, versatile gear cutting process. The developevd kinematic model is applied in a dexel-based solid modeling engine to extract three-dimensional uncut chip geometry, from which the two-dimensional cross section is obtained via Delaunay triangulation. Cutting velocities along discretized cutter edges are calculated and used to determine the effective rake and oblique angles. Then, force predictions are made using the oblique cutting model and validated using measurements from power skiving trials performed on a DMG MORI NT5400DCG mill-turn machine.

Shaping is a versatile process for machining gear teeth on complex monolithic components, which cannot otherwise be produced using other methods (like hobbing) due to geometric constraints. This paper presents a new model to accurately predict the chip geometry and cutting forces in shaping. Kinematics of gear shaping is modeled and verified. Cutter–workpiece engagement is predicted using a dexel-based geometric modeler, and refined by alpha-shape reconstruction. Varying rake and oblique angles are resolved along the cutting edges and used in three-dimensional force predictions. Simulated forces are shown to agree closely with those measured on a gear shaping machine.