Key Takeaways & Executive Findings
- •• A novel contact performance-driven method enables skiving of both face gear and pinion with a single cutter, eliminating separate cutters and reducing costs. • The two-stage optimization model improves contact performance, reducing maximum tooth surface contact stress by 31.7% and avoiding edge contact. • Simulation and rolling tests confirm the consistency of tooth surface contact patterns, validating the method's effectiveness. • The proposed approach offers a practical reference for cutting edge design of skiving cutters for face gear drives.
Abstract
This study develops a contact performance-driven method for skiving face gear drives using a single cutter, eliminating the traditional need for separate cutters to reduce production costs and time. First, the mathematical models of the tooth flanks for the face gear drives are established based on the gear skiving processes. Then, load tooth contact analysis (LTCA) model is established to calculate the contact performance data. Next, a two-stage optimization model is employed to determine the optimal parameters of the cutting edge with improved contact performances. The effectiveness of this method is validated through simulations and rolling tests. Compared with the traditional method, the proposed method can machine both the face gear and its mating pinion with a single cutter. Simulation results show that the proposed method avoids tooth surface edge contact, with the maximum tooth surface contact stress reduced by 31.7%, the contact ratio decreases by 21.5%, and the transmission error increases by 22.3%. Rolling tests verify the consistency of tooth surface contact patterns between simulations and experiments. The proposed method provides a reference for the cutting edge design of skiving cutters for face gear pairs.
1. Introduction
Gear skiving technology was invented in 1910 [1], and it has become a highly competitive technology in manufacturing cylindrical gear, spline parts, and worm [2], as it can offer a superior surface finish and a high machining efficiency compared to other methods, such as hobbing [3], broaching, and shaping [4].
The cutting edge design of the gear skiving cutter is the key to determining the machining accuracy. However, the skiving cutter's inherent errors and the cutting edge's longitudinal deviation contribute to the gear profile's inaccuracies [5]. This makes it difficult to achieve high-precision skiving of gears, especially for some gears with complex geometric tooth surfaces, such as face gears and bevel gears. To address this, academia has proposed solutions: 1) optimizing the cutting-edge of skiving tool and, 2) optimizing the cutting path to compensate for tooth surface errors.
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TANG Zhong-wei, ZHOU Yuan-sheng, MO Shuai, TANG Jin-yuan, MA Chi, ZHANG Wu-ji, HE Hai-yu (2026). An innovative design driven by contact performances for skiving of spur face gear drive with single cutter. Journal of Central South University. https://doi.org/10.1007/s11771-026-6182-9
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Frequently Asked Questions
What is the main innovation of this paper?
The paper proposes a contact performance-driven method for skiving face gear drives using a single cutter, eliminating the need for separate cutters for the gear and pinion, thus reducing production costs and time.
How does the proposed method improve contact performance?
The method uses a two-stage optimization model to determine optimal cutting edge parameters, which reduces maximum tooth surface contact stress by 31.7%, avoids edge contact, and maintains consistent contact patterns as verified by rolling tests.
What are the key simulation results?
Simulation results show that the proposed method avoids tooth surface edge contact, reduces maximum contact stress by 31.7%, decreases contact ratio by 21.5%, and increases transmission error by 22.3% compared to traditional methods.
How is the method validated?
The method is validated through both simulations and rolling tests, which confirm the consistency of tooth surface contact patterns between simulations and experiments.
What is the significance of this work for gear manufacturing?
This work provides a reference for cutting edge design of skiving cutters for face gear pairs, enabling efficient and cost-effective production of high-quality face gear drives.
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