The method of
ultrasonic lapping of spiral-bevel and hypoid gears were firstly presented.The material removal mechanism of
ultrasonic lapping of the gears were investigated and specified as abrasives hammering to micro-cut,bouncing to impact and slurry cavitation.The experimental comparison between
ultrasonic lapping and conventional one shows that the material
removal rate of the ultrasonic lapping is three times that of the conventional one,and the ultrasonic lapping produces a better tooth surface quality,roughness Ra 0.2μm,sectional height c=1.2μm for bearing length ratio of profile Rmr(c)=100%.Based on the orthogonal experimental design,the optimal combination of the ultrasonic lapping parameter levels for removal rate is determined as torque at pinion,0.05Nm;pinion rotational speed,600 r/min;slurry concentration,20% by weight;the contribution by percentage of torque,speed and concentration are of 9.6,16.7 and 64.7,respectively.Finally,a good agreement between the predicted and actual removal rate for the optimal lapping parameters is observed.