Skiving is an efficient gear cutting technology with relatively high machining accuracy, especially for internal gears. Nevertheless, the machining accuracy can hardly be satisfied if the skived gear is modified, so we try to extend the definition and hypotheses domain of the previous works. In this paper, fundamental research is conducted to further improve the skiving accuracy. Firstly, a new type of skiving tool with double rake faces is proposed for flexibly meeting different modification requirements of the two flanks of the work gear teeth. Secondly, the mathematical model of curve-surface conjugated cutting edges of the skiving tool for enveloping the tooth flanks of the working gear with profile modification is established. Then, the algorithm of the skiving tool path with alterable shaft angle in the cutting process is proposed for eliminating the twist of gear tooth flanks with lead modification. Finally, machining simulations are carried out to verify the feasibility of the proposed improved skiving methods.

Gear skiving is an efficient and high-precision gear processing method, particularly advantageous for internal gears and coupling gears. However, the main limitation of its application is the rapid wear of skiving tools. This paper combines simulation analysis and numerical calculations to reveal the essential characteristics of the gear skiving process and the fundamental causes of tool wear. Firstly, it researches the distribution of cutting loads on the tool edges through the kinematic simulation analysis of gear skiving. Then, it analyzes the changing rule of working angle, clearance angle, tool inclination, and cutting speed and reveals the cutting state and chip flow patterns during the skiving process through numerical simulation calculations of gear skiving. Finally, it investigates the chip formation mechanism and the stress variation rule on the tool edges through finite element simulation of gear skiving. These analyses and calculations provide optimization guidance and methods for improving the cutting performance and the service life of skiving tools.

Ring gear is an important transmission component, but restricted by its ring-shape structure, the tooth surfaces are pretty hard to be finished after heat treatment. Honing is the most commonly used finishing technique for external gear, but for ring gear, it is inconvenient. In this paper, a new type of cone-shape honing wheel is proposed and the honing mechanism is studied for improving the honing performance of ring gear. First of all, the mathematical model of the honing technology by use of cone-shape honing wheel is built, and the merits of the new honing method are discussed. Then, the contact conditions between the honing wheel and the work gear are analyzed, and it is found that the tool tilt angle of the honing wheel has good influences on the honing mark distribution of the work gear. Finally, the honing simulations for ring gear by use of cone-shape honing wheel are carried out, by which the feasibility of the new honing technique are verified.