• 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.