Research on the Tooth Modification
ting force for the skiving of periodic structures through a numeri-
in Gear Skiving
Fangyan Zheng
School of Mechanical Engineering,
Chongqing University of Technology,
Chongqing 400000, China
Mingde Zhang1
School of Mechanical Engineering,
Chongqing University of Technology,
Chongqing 400000, China
Weiqing Zhang
School of Mechanical Engineering,
Chongqing University of Technology,
Chongqing 400000, China
Xiaodong Guo
School of Mechanical Engineering,
Chongqing University of Technology,
Chongqing 400000, China
As a prospective machining method for cylindrical gear, gear
skiving has been promoted by many commercial companies, such
as Gleason, Mitsubishi, and Prawema recently. Although the prin-
ciple and mathematical model for gear skiving has been discussed
by many works, the tooth modification was left behind in the liter-
ature. In fact, machine kinematics correction and tooth contact
analysis (TCA) are widely used for tooth modification in gear
processing, such as hobbing, grinding, and milling. Focusing on
this, the paper generalizes machine kinematics correction and
TCA to gear skiving. The influence of the modification parameters
on tooth deviation, contact path, and transmission error are all
investigated, showing that localized contact pattern and polyno-
mial transmission error can be realized through cutter offset cor-
rection for one gear and cutter tilted (or crossed angle)
correction for the other gear. [DOI: 10.1115/1.4040268]
Keywords: gear skiving, tooth modification, tooth contact analysis
1 Introduction
Gear skiving is a highly productive cutting method, both for exter-
nal and internal gear types, which removes the materials through the
sliding velocity between the crossed axis of the cutter and workpiece
[1–3]. This method, which has been invented by Pittler for a century
[4], is regarded as the ideal process for machining internal gear in
theory. However, due to the short cutter life and low machine tool
stiffness, for a long time, the gear skiving technology has witnessed
rather slow development. More recently, along with the performance
enhancement of the machine tool and cutter materials, the power
skiving technology showed superiority in mass production, espe-
cially for internal gears. Under such circumstance, many commercial
companies, such as Gleason, Mitsubishi, and Prawema have
researched the solution for power skiving, including skiving machine
tool, skiving cutter, cutting process, and other related issues [5–7].
Following the development of the gear skiving technology,
many works were devoted to its theory and application: Spath and
1 [39,40]:
Corresponding author.
Contributed by the Power Transmission and Gearing Committee of ASME for
publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received November
27, 2017; final manuscript received April 28, 2018; published online June 1, 2018.
Assoc. Editor: Mohsen Kolivand.
Journal of Mechanical Design Copyright V
C 2018 by ASME
Heuhsam [8] investigated the cutter design, cutter angle, and cut-
cal method; Sugimoto et al. [9] investigated the performance of
skiving hobs in finishing induction hardened and carburized gears;
Antoniadis et al. [10] illustrated an involved algorithm to simulate
nondeformed chips and the cutting force in gear skiving process;
Bouzakis et al. [11] synthesized the theory and practice of cylin-
drical gear skiving through its comparison with other generating
methods; Radzevich [7] introduced the design and computation
principle of the skiving cutter for gear skiving; Antoniadis [12]
simulated the kinematics of the cutting process with the aid of
commercial CAD software, which allows the precise determination
of the nondeformed chips and cutting forces; Chen et al. [13] pro-
posed a cutter design approach to error-free gear skiving;
Kobialka [6] introduced the premachining solution for gear skiv-
ing process, which showed great prospect for reduction of lead
time and improvement of gear quality; Moriwaki et al. [14] pro-
posed a tooth geometry design method for cylindrical skiving cut-
ter based on a conjugate pinion mating with an internal gear under
a shaft angle condition; Stadtfeld [15] introduced the power skiv-
ing technology of Gleason, including the generation kinematics,
cutter geometry, chip geometry, machine tool configuration, and
processing software; Guo et al. [16] investigated the skiving tool
design and cutting mechanism of cylindrical gears; Tomokazu
et al. [17] established a calculation model for internal gear skiving
with a pinion-type cutter having pitch deviation and run-out; Tsai
[18] established the mathematical model for design and analysis
of power skiving tool for involute gear cutting; Guo et al. [19]
researched the theoretical tooth profile errors of gears in skiving,
finding that the conventional skiving tools are defective in high-
accuracy gear machining; Besides, they also investigated the tool set-
ting errors on gear skiving accuracy [20]; Moriwaki et al. [21] inves-
tigated the cutting tool parameters of cylindrical skiving cutter with
sharpened angle for internal gears to optimize skiving cutter design.
However, all these works have failed to investigate the tooth
modification in gear skiving process. In practice, proper tooth
modification can help reduce sensitivity of installation and proc-
essing errors, which is very important in modern gear industry
[22,23]. In face-hobbing and face-milling process for spiral bevel
gears, tooth modification was obtained through syntheses of gear
design and machine tool setting by many researchers, such as Fan
[24,25], Simon [26,27], Shih and Fong [28], Zhang-Hua Fong
[29] and Zheng et al. [30–32]; for cylindrical gear hobbing, many
works were focused on the tooth surface modification through cut-
ter modification and generating kinematics correction [33–35]; for
cylindrical gear grinding, tooth modification was realized though
grinding wheel correction and grinding motion control [36–38].
All these researches show that in gear machining, tooth modifica-
tion can be realized through correction of the cutter location and
generating kinematics. Besides, among these works, the concept
and algorithm of TCA is used to investigate the performance of
tooth modification.
The paper generalizes the machine kinematics correction and
TCA to gear skiving. The principle and mathematical model for
three proposed tooth modification methods are investigated. The
influence of the modification parameters on tooth surface devia-
tion, tooth contact pattern, and transmission error are discussed.
The numerical results then show that an ideal gear modification of
localized contact pattern and polynomial transmission error can
be realized through cutter offset correction for one gear and cutter
tilted (or crossed angle) correction for the other gear.
2 The Mathematical Model of Gear Skiving
The geometry of skiving cutter is similar to a shaper cutter used
in gear shaping, which can be simplified as a helix gear as follows
Rce ðuÞ ¼ ½ rc cos at ðcosu þ usin uÞ rc cosat ðsin u  ucos uÞ 0 1T
(1)
AUGUST 2018, Vol. 140 / 084502-1
 Fig. 1 Coordinate system for gear skiving

Table 1 Design data for helix gear pair

where rc refers to the pitch radius of the cutter, and at is the end
Pinion Gear
pressure angle of the cutter.
As shown in Fig. 1, ug is the angle of the gear, uc is the angle Center distance (mm) 21.893
of the cutter, E is the center distance between the gear and the cut- Normal module (mm) 2.5
ter, and sf is the feeding distance. Four coordinate systems are Normal pressure angle (deg) 20
established to illustrate the kinematic relations in gear skiving: Tooth addendum (mm) 2.5 2.5
Coordinate system S0 is fixed on the ground, in which the origin is Tooth dedendum (mm) 3.125 3.125
the gear center, and z0-axis is along the gear axis; coordinate sys- Helix angle (deg) 24 24
tem Sg is attached on the gear with an angle ug relative to S0 ; Hand of spiral RH RH
Tooth number 27 42
Coordinate system S1 is also fixed on the ground, of which the ori-
Pitch radius 36.944 58.837
gin is the cutter center, and z1 -axis is along the cutter axis; Coordi- Length width 20 20
nate system Sc is attached on the cutter with an angle uc relative
to S1 . The relation between the cutter and the gear is as follows:
Mgc ðug ; sf Þ ¼ Mg0 ðug ÞM01 ðsf ÞM1c ðug Þ (2) Table 2 Cutter data for the gear skiving

where Normal module (mm) 2.5

Normal pressure (deg) 20
2 3 Pitch radius (mm) 35
cos ug sin ug 0 0
6 7 Helix angle (deg) 0
6 sin ug cos ug 0 07 Tooth number 28
Mg0 ¼ 6
6 0
7
4 0 1 075
Tooth addendum (mm) 3.125
Tooth dedendum (mm) 3.125
0 0 0 1
2 3
cos R 0 sin R E In order to illustrate the correctness of the mathematical model
6 7
6 0 1 0 07 above, a helix gear pair with data listed in Table 1 is skived by a
M01 ¼ 6
6 sin R
7 cutter with data shown in Table 2. For each of the gear tooth, the
4 0 cos R sf 7
5 enveloped surface is of complicated geometry as shown in Fig. 2,
0 0 0 1 and the boundary curve (heavy red curves) is the tooth profile gen-
2 3 erated in each feeding distance.
cos uc sin uc 0 0
6 7
6 sin uc cos uc 0 07
M1c ¼ 6
6 0
7 3 Tooth Modification of Gear Skiving
4 0 1 07 5
0 0 0 1 3.1 Cutter Offset Correction. In the cutter offset correction
method, the direction of the cutter feeding is no longer along the
gear axis, but following a curve trace as shown in Fig. 3. The cut-
Based on the cutting edges (Eq. (1)) and coordinate transforma- ting depth for each feeding distance is different and brings varia-
tion between the cutter and gear (Eq. (2)), the envelope surface of tion of tooth thickness along the tooth lengthwise direction.
the cutter edges can be obtained [2] Hence, the center distance between the gear and cutter should be
Rge ðug ; sf ; uÞ ¼ Mgc ðug ; sf ÞRce ðuÞ (3) represented as follows:

E0 ðsf Þ ¼ rg þ rc þ a0 þ a1 ðsf  a2 Þ2 (5)

Based on the meshing theory, the generated tooth surface can
be obtained through the following meshing theory [41]:
n0e ðug ; sf ; uÞ  vgc ðug ; sf ; uÞ ¼ 0
where n0e is the normals of the cutter surface, and vgc is the rela-
tive velocity between the cutter and gear in S0 , which can be cal-
culated as in Ref. [42].
where a0 ; a1 … are the coefficient for quadratic interpolation.
(4) Thus, through replacing parameter E in Eq. (2) with E0 ðsf Þ, the
tooth surface with cutter offset correction can be obtained.
3.2 Cutter Tilted Correction. In the cutter tilted correction
method as illustrated in Fig. 4, the theoretical generating tooth

084502-2 / Vol. 140, AUGUST 2018 Transactions of the ASME

 Fig. 2 Illustration of tooth surface enveloped by feeding motion at left (a) and right (b) sides

Table 4 List of pinion and gear in each case for TCA

Pinion Gear

Case C0 Case P0 Case G1

Case C1 Case P0 Case G2
Case C2 Case P0 Case G4
Case C3 Case P0 Case G5
Case C4 Case P0 Case G7
Case C5 Case P0 Case G8
Case C6 Case P0 Case G9
Case C7 Case P1 Case G1
Case C8 Case P1 Case G7
Fig. 3 Illustration of tooth thickness modification in gear Case C9 Case P1 Case G9
skiving

E00 ¼ ðrg þ rc Þ= cos Rt þ a1 ðsf  a2 Þ2 (6)

Besides, the coordinate transformation matrix from Sc to S1

should also be renewed
2 3
cos dt 0 sin dt 0
6 7
6 0 1 0 07
M1c ¼ 66 7
7
4 sin dt 0 cos dt 0 5
0 0 0 1
2 3
cos uc sin uc 0 0
6 7
Fig. 4 Illustration of cutter tilted in gear skiving 6 sin uc cos uc 0 0 7
66 0
7
7 (7)
4 0 1 r c tan R t5
0 0 0 1
profile is the projection of the cutting edges on the gear edges sur-
face. With the cutter tilted, the center distance between cutter and Thus, through renewing E00 and M1c , the tooth surface with cut-
gear must be renewed as E00 , which can be calculated as ter offset and tilted corrections can be obtained.

Table 3 Tooth modification parameters for pinion and gear in each case

Pinion/gear

Shaft offset modification (mm)

Tilted angle dt (deg) Crossed modified angle Rc (deg) a0 a1 a2

Case P0/G0 0 0 0 0 0
Case P1/G1 0 0 0 0.001 0
Case P2/G2 0 0 0 0.002 0
Case P3/G3 0 0 0 0.002 0
Case P4/G4 0 0 0 0.001 2.5
Case P5/G5 0 0 0 0.001 2.5
Case P6/G6 0 0 0.05 0 0
Case P7/G7 3 0 0 0 0
Case P8/G8 5 0 0 0 0
Case P9/G9 0 1 0 0 0

Journal of Mechanical Design AUGUST 2018, Vol. 140 / 084502-3

 Fig. 5 Tooth surface deviation topography for pinion (a)–(l) in case P0–P9 (unit: lm)

3.3 Crossed Angle Correction. Apart from the above two
methods, the change of crossed angle between the cutter and gear
can also be applied to gear modification. In this method, the
crossed angle is no longer R, but becomes R0 ¼ R þ Rc , and Rc is
the crossed correction angle. With R replaced by R0 in the above
mathematical model, the gear tooth surface after crossed angle
correction can also be obtained.
4 Case Study
In order to investigate the influence of tooth modification on tooth
surface of the gear designed above, ten cases with different modifica-
tion parameters for the pinion and gear are listed in Table 3.
Besides, in order to investigate the contact performance of the
modified tooth surface, the algorithm for unload tooth contact

084502-4 / Vol. 140, AUGUST 2018 Transactions of the ASME

 Table 5 Contact pattern in both gear surface sides

Journal of Mechanical Design AUGUST 2018, Vol. 140 / 084502-5

 Table 6 Transmission error for both gear surface sides
analysis (TCA) of the gear drive is applied for contact pattern esti-
mation and transmission error prediction in which a thickness of
0.0065 mm [22] is employed. Ten cases of contact pairs, as listed
in Table 4, are used to investigate the influence of tooth modifica-
tion on contact path and transmission error.
4.1 Influence on Tooth Deviation Topography. For each
case in Table 3, surface deviation topography for the pinon is
illustated in Fig. 5. The gray grid represents the theoretical tooth
084502-6 / Vol. 140, AUGUST 2018
profile, and the blue heavy grid refers to the modified tooth
surface.
In case P0 without modifiecation as shown in Fig. 5(a), the
deviation is found to be zero at all points, proving the corectness-
ness of the above mathematical model.
4.1.1 Influence of Cutter Offset Correction. Through compar-
ing cases of P0, P1, P2, and P3, it is found that change of parame-
ter a1 will result in crown teeth. The modified surface at both ends
are inside the theoretical surface when a1 > 0 (Figs. 5(b) and
Transactions of the ASME
 Table 6 (Continued)
5(c)) while outside the theoretical surface when a1 < 0
(Fig. 5(d)); The deviation increase along with the increase of a1 ;
the deviation increases from the root to the tip on one end and
decreases on the other end, meaning that the crowned tooth flank
is slightly twisted.
Through comparing cases of P1, P4, and P5, the parameter a2 is
found to influence the zero deviation points. They are located in
the middle of the tooth surface if a2 ¼ 0 (Fig. 5(b)), and close to
one end side if a2 > 0 (Fig. 5(e)) while close to the other end side
if a2 < 0 (Fig. 5(f)).
Through comparing cases of P0 and P6, parameter a0 is found
to make the modified surface equally offset the theoretical surface
and the offset direction is decided by the symbol of parameter a0 .
4.1.2 Influence of Cutter Tilted. As shown in the cases of P7
and P8 (Figs. 5(h) and 5(i)), it is found that: (1) the tooth thickness
increases regardless of the cutter tilted direction; (2) the point
deviations at tooth root is larger than that at tooth tip; (3) the devi-
ations is different for the left and right tooth flank.
4.1.3 Influence of Crossed Angle. Through comparing cases
of P0 and P9 (Figs. 5(a) and 5(j)), it is found that: (1) the increase
and decrease of tilted angle and the profile deviation at the tip and
the root in all the lengthwise sections are decreased; (2) the tip
point deviations are larger than the root point deviations, meaning
that a cutter tilted will bring a change in pressure angle.
Journal of Mechanical Design
4.2 Influence on Tooth Contact. As listed in Table 4, TCA
is applied to ten contact cases from C0 to C9. The result of contact
pattern and transmission error at both gear tooth surface sides are
obtained, as shown, respectively, in Tables 5 and 6.
4.2.1 Influence of Quadratic Interpolation Coefficient.
Through comparing cases C0 and C1, it is found that the change
of parameter a1 will result in a localized tooth contact. The instant
contact line inclines toward different end sides for pinion and
gear; the contact point trace line also inclines but toward a differ-
ent direction from the instant contact line; the instant contact
length is decreased along with the increase of parameter a1 ; the
transmission error is increased along with the increase of a1 ;
the shape of transmission error curve is found to be different for
the left side and the right side; the amplitude of the error curve is
smaller for the left side than the right side.
In comparing cases C0, C2, and C3, parameter a2 is found to
influence the location of contact point trace line, which is in the
middle of the tooth surface if a2 ¼ 0, close to one end side if a2 >
0 and close to the other end side if a2 < 0. Besides, parameter a2
also influences the transmission error: Along with both its increase
and decrease, the transmission error is increased for the left side
of tooth surface and decreased for the right side.
4.2.2 Influence of Cutter Tilted. As shown in cases C4 and
C5, the contact point trace line is along the edge of the tooth
AUGUST 2018, Vol. 140 / 084502-7
surface, and the contact line is shortened along with the increase
of the tilted angle (in this case, if the instant contact line is short
enough, edge contact will occur); the length of the instant contact
line is shorter at the left tooth surface side than that at the right
side, meaning that the contact performance at the left side is worse
than that at the right side; the transmission error at the left side is
larger than that at the right side, showing again a relatively worse
meshing performance at the left side.
4.2.3 Influence of Crossed Angle. As is shown in case C6,
with crossed angle correction, the gear pair is of point contact,
and the trace line of the contact point is close to the edges of tooth
surface, similar to the case with cutter tilted modification; the
instant contact lines are long enough to cross the whole tooth
surface, similar to the contact of the standard gear pair
without modification, showing that crossed angle modification
exerts little influence on the contact lines; the influence of crossed
angle on transmission error is similar to that with cutter tilted
modification.
4.2.4 The Comprehensive Influence. The above discussions
shows that cutter offset modification can help to crown the tooth
geometry and localize the contact pattern.
In comparing C7 and C0, if both the pinion and gear are set
with cutter offset modification, the instant contact line is found to
be shortened, while only a little change takes place in the trans-
mission error.
In C8, different from C4, the pinion is set with cutter offset cor-
rection, and the contact pattern is hence localized. The amplitude
of transmission error remains the same, but the shape of the trans-
mission error becomes close to the shape of a quadratic function.
In other words, both the contact pattern and transmission error are
better in C8 than that in C4.
Besides, similar rule is also found in comparing C9 and C6, in
which a pinion under cutter offset correction is meshed with a
gear under crossed angle correction.
The above comparisons show that with cutter offset modifica-
tion of one gear, both the contact pattern and transmission error
are improved. And the best contact pattern and transmission error
among all cases belong to cases C8 and C9, in which the gear
under cutter offset correction is meshed with cutter titled or gear
under crossed angle correction.
5 Conclusions
This paper proposes three tooth modification methods in gear
skiving and investigates the influence of tooth modification
parameters on tooth surface deviation, contact pattern, and trans-
mission error. Several conclusions can then be drawn as follows:
(1) Cutter offset correction, cutter tilted correction and crossed
angle correction are found as three easily realizable meth-
ods for the tooth modification of skived gear.
(2) Cutter offset correction can realize the tooth surface crown-
ing, tooth thickness changing, and contact pattern localiza-
tion, but the crowned teeth are of slight twist, which in turn
will result in transmission error.
(3) Cutter tilted correction and crossed angle correction are
found to make the tooth profile a same deviates in each end-
ing section and the tooth thickness change, thus result in
transmission error and even edge contact.
(4) The localized contact pattern and polynomial transmission
error, which is common regarded as ideal for gear modifica-
tion design, can be realized through cutter offset correction
for one gear and cutter tilted (or crossed angle) correction
for the other gear (see C8 and C9 in Tables 5 and 6).
However, all the investigations are conducted under unloaded
assumptions, and further works should be addressed on the modi-
fication with loaded contact analysis.
084502-8 / Vol. 140, AUGUST 2018
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