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Bruno Vargas, M.Sc.

Research Associate
department: Manufacturing and Materials Technology
office hours: To be agreed
room: Geb.10.92, 102
phone: +49 1523 9502625
Bruno VargasOnq0∂kit edu

76131 Karlsruhe
Kaiserstraße 12

Bruno Vargas, M.Sc.

Area of Research:

  • Gear cutting technology
  • Gear skiving
  • Kinematic simulation of gear cutting processes



  • Gear skiving with small axis crossing angles


General Tasks:


Test benches:

  • Gear skiving machine Index V300


Dissertation: Gear skiving with small axis crossing angles



14/08/1987 Born in Belo Horizonte (Brazil)
03/2007-06/2012 Mechanical Engineering (B.Sc.), Federal University of Minas Gerais (UFMG), Belo Horizonte (Brazil)
Theme: “Dimensional and geometric deviations induced by face milling of tool steel AISI D2 tool steel”
09/2010-02/2011 Research project (internship), Mapal Dr. Kress, Aalen
Theme: „Cutting edge preparation of CBN precision cutting tools”
07/2012-06/2015 Mechanical Engineer, Kotchergenko Engenharia, Belo Horizonte (Brazil)  
02/2014-02/2016 Mechanical Engineering (M.Sc.), Federal University of Minas Gerais (UFMG), Belo Horizonte (Brazil)
Theme: „Numerical–experimental vibration analysis of the main spindle of a machining center“
Seit 06/2016 Research Associate at the Institute of Production Science (wbk) at Karlsruhe Institute of Technology (KIT)



[ 1 ] Vargas, B.; Klose, J.; Zanger, F. & Schulze, V. (2019), "Simulative and Experimental Investigation of Gear Skiving with Reduced Axis Crossing Angles ". GETPRO, eds. Forschungsvereinigung Antriebstechnik e.V. (FVA), pp. 235-244.
Gear skiving has been increasingly used in the production of internal gears and shows high potential to manufacture external gears with adjacent shoulders. In order to avoid tool – workpiece collision, it is possible to minimize the length of tool overrun by reducing the axis crossing angle. However, the process kinematics changes with this reduction, representing a big challenge to the process design. In order to fulfill the lack of detailed knowledge and establish its industrial practice, simulative and experimental studies with axis crossing angles Σ between 5° and 15° were conducted. A three-dimensional kinematic simulation of gear skiving based on penetration calculation was carried out to demonstrate the influence of the process parameters on the local cutting conditions. The results show that the local rake angle reaches extremely negative values at the tooth tip of the cutting tool, which is usually characterized by the highest wear rates and therefore is critical for tool life. In order to relieve the local rake angles inherent to the unfavorable kinematics, both the tool geometry and the process can be optimized. Therefore, the simulations demonstrate how the constructional rake angle and the multiple infeed strategy can positively influence the local rake angle. In order to investigate how the local cutting conditions influence the cutting forces, wear behavior and tool life, tests with single-toothed tools were conducted for different axis crossing angles. The influence of the infeed strategy, tool rake angle and maximum uncut chip thickness on the local cutting conditions were investigated and different wear behaviors for axis crossing angles less than 10° were observed, suggesting a process limit regarding tool life. For smaller angles, the influence of the investigated parameters is very pronounced and the process design is limited to a narrow but still existing parameter window.

[ 2 ] Vargas, B.; Zapf, M.; Klose, J.; Zanger, F. & Schulze, V. (2019), "Numerical Modelling of Cutting Forces in Gear Skiving". Procedia CIRP 82, eds. Elsevier B.V., pp. 455-460.
Gear skiving is a high-performance machining process for gear manufacturing. Due to its complex kinematics, the local cutting conditions vary during tool engagement. Particularly, the local rake angle can reach highly negative values, which have a significant effect on the cutting force. In this paper, the Kienzle force model with additional coefficients was implemented in a numerical model to calculate local cutting forces considering the influence of local rake angle. The experimental validation based on total cutting forces shows good results and indicates an increase of model accuracy for a wide parameter range by considering the rake angle Variation.