A flexible method to correct tooth surface deviation for CNC power skiving of face gears

In contemporary gear manufacturing, power skiving stands out as an efficient process. Therefore, several investigations have applied the skiving process to face gear. However, obtaining the precision of the skived tooth surface is a challenge. So, this study introduces a groundbreaking approach to enhancing face gear manufacturing productivity by addressing deviations in the spur face gear tooth surface arising from geometric and kinematic constraints in the conventional power skiving method. To overcome the limitations in traditional approaches, the development of a flexible model for calculating coefficients that adjust CNC axes’ motion and modify the rack cutter was established. The modified tooth topology of the face gear can be obtained by adjusting the machine axis of the CNC machine. A sensitivity correction technique is employed to implement this flexible correction method, utilizing the Levenberg–Marquardt (LM) algorithm to determine the coefficients governing machine motion. The primary objective is to achieve the necessary normal deviations on the tooth surface of the spur face gear. The effectiveness of the proposed method is confirmed by using numerical examples featuring various predetermined target surfaces alongside corresponding machining simulations.