New methodology for determining basic machine settings of spiral bevel and hypoid gears manufactured by duplex helical method

• A general calculation approach for basic machine settings is proposed.
• Three reference points are used to determine the optimal machine settings.
• Blank design theory of spiral bevel gears with the duplex depth taper is described.
• Tooth bearings and functions of transmission error on the both sides are favorable.

The duplex helical method is an advanced and primary manufacturing method of face milled spiral bevel and hypoid gears for its characteristics of higher efficiency, lower cost, higher strength and power dry cutting. A new methodology for calculating the basic machine-tool settings of spiral bevel and hypoid gears manufactured by the duplex helical method is proposed in this work. Firstly, the blank design theory of spiral bevel and hypoid gears with the duplex depth taper is described in detail. In order to obtain the optimal machine settings, three reference points are defined. The basic machine settings for spiral bevel and hypoid gears manufactured by the duplex helical method in accordance with the five steps are determined. Finally, a hypoid gear set generated by the duplex helical method is used as an example to validate the developed methodology. The results reveal that the tooth bearings and the transmission error functions on the drive and coast sides are favorable, and the results of the simulation and experiment are consistent.