Skiving of Spur Face Gears and Verification of Meshing Performance of Modified Gear Pair

Power skiving has become an increasingly adopted process for manufacturing spur face gears. However, achieving satisfactory meshing performance remains challenging, mainly because the tooth surface produced by skiving does not fully coincide with the ideal conjugate surface, while direct modification of the face gear is relatively difficult in practice. To overcome this limitation, a meshing performance regulation strategy is developed by applying topological modification to the mating cylindrical gear. First, the geometry of the skived spur face gear is mathematically formulated. Subsequently, the modified tooth flank of the cylindrical gear is generated using a rack surface described by a bivariate quadratic function. The deviations of the two mating tooth surfaces were mapped to construct an ease-off difference surface, from which the contact ellipse, contact path, and geometric transmission error were evaluated. For modification coefficients of a1 = −9.03 × 10−5 mm−1, a2 = −5.0 × 10−4 mm−1, and a3 = −1.0 × 10−3 mm−1, the calculated transmission error amplitude was 6.362 μrad. The predicted contact ellipse had an inclination angle of 14.13°, while rolling tests gave approximately 14.6°. The experimental to numerical deviations in inclination angle, tooth length ratio, and tooth depth ratio were 0.5°, 7.1%, and 8.0%, respectively. These results demonstrate that modifying the mating cylindrical gear provides a practical means of controlling the meshing performance of skived spur face gear pairs.