Large Spiral Bevel Gears on Universal 5-axis Milling Machines: A Complete Process

The cutting of bevel gears on universal 5-axis milling machines represents a promising solution to replace the conventional cutting process. The process is highly flexible and does not require neither special gear generating machines nor special tools. Thus, it is particularly suitable for small batches, prototypes or to obtain a specific and unique product. In this way, we have focused on the machining of a large-sized spiral bevel gear, from the initial design to the final machining. A gear will be machined using different milling paths and scallop heights. Each of the different strategies will be applied in consecutive teeth, and afterwards these teeth will be analyzed to check some of the gear quality parameters (roughness, profile angle variation, single pitch error...) with the final goal of finding the optimal cutting strategy. As finishing tool, an air turbine finishing tool was evaluated as an alternative technology apart from the typical tapered ball end mill.