Research on a hybrid modeling method of a spiral bevel gear based on cutter simulation

Spiral bevel gears are essential components of mechanical devices; however, it is difficult to design, manufacture, and inspect them because their shapes are difficult to model on a computer. In this study, a method for modeling spiral bevel gears manufactured using a Gleason machine was investigated. The method to generate a gear tooth profile as point data and calculate transformation matrices between coordinate systems based on the machining process is explained in detail. The cutting volume is determined using multiple cross-sectional profiles created along the tool path, and the final gear shape is generated by subtracting the cutting volume from the workpiece. A spiral bevel gear modeling system is developed based on the proposed method, and its reliability is verified by measuring the actual gear and comparing it to the modeled shape. The verification results indicated that the modeled shape showed a 7.1 µm difference from the sample gear, implying that the proposed modeling method is reliable for modeling spiral bevel gears.