A novel correction method to attain even grinding allowance in CNC gear skiving process

Power skiving is currently an efficient machining process to manufacture gears. In practical applications, uneven gear profile deviations caused by the asymmetric cutting edge of a skiving cutter affect gear profile accuracy and finishing cost. Therefore, this paper proposes a novel method to attain the even grinding allowance on both gear flanks in the CNC skiving. A quadratic polynomial function is adopted to correct an asymmetric rack profile, which is used to generate the skiving cutter profile. Pressure angles, protuberances, and polynomial coefficients on two sides of the rack are determined analytically according to the requisite grinding allowance and the conjugation relationship between the gear and the cutter. Skived tooth profiles for internal/external gears are simulated based on the CNC machine motion, and its normal deviation can be estimated. As the numerical results demonstrate, the profile deviations on both gear flanks are close to the required settings, and the even grinding allowance is achieved on the active involute sections. Additionally, a radial basis function (RBF) regression model is constructed to conveniently determine the design parameters of the skiving cutter.