A design method for the geometric shape and modification of asymmetric spur gear was proposed, in which the geometric shape and modification of the gear can be obtained directly according to the rack-cutter profile. In the geometric design process of the gear, a rack-cutter with different pressure angles and fillet radius in the driving side and coast side was selected, and the generated asymmetric spur gear profiles also had different pressure angles and fillets accordingly. In the modification design of the gear, the pressure angle modification of rack-cutter was conducted firstly and then the corresponding modified involute gear profile was obtained. The geometric model of spur gears was developed using computer-aided design, and the meshing process was analyzed using finite element simulation method. Furthermore, the transmission error and load sharing ratio of unmodified and modified asymmetric spur gears were investigated. Research results showed that the proposed gear design method was feasible and desired spur gear can be obtained through one time rapid machining by the method. Asymmetric spur gear with better transmission characteristic can be obtained via involute modification.

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The meshing characteristic of asymmetric involute spur gear was studied, the equations of the geometric shape of the asymmetric gear for both sides were deduced, and the equations of contact ratio and the key points of contact were also obtained. Meanwhile, an involute slope modification method considering the effects of static transmission errors was proposed based on the meshing properties. The characteristic of the involute slope modification was analyzed by changing different modification parameters. The mesh stiffness and synthetic mesh stiffness of unmodified and modified asymmetric spur gears were investigated. Furthermore, the spectrums of synthetic mesh stiffness under different modification parameters were compared. Research results showed that the modification parameters influence the meshing performance of gear pairs, and the proposed modification method was feasible to improve the transmission performance of gear pairs with appropriate modification parameters.

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