Implementation of an exact completing method of generation for face-milled spiral bevel gears with uniform depth taper

This paper proposes an exact completing method of generation of face-milled spiral bevel gears with uniform depth taper. This method ensures localized bearing contact without kinematic transmission errors in both directions of rotation. Both sides of the tooth are generated simultaneously using the same set of basic machine tool settings. A tip relief on the tooth surfaces is the only required microgeometry modification to achieve a smooth transition of load between consecutive pairs of teeth. An analytical approach to determine the basic machine tool settings and select the grinding cutter parameters has been also developed. The selection of the nominal cutter radius follows the recommendations of Information Sheet AGMA 22849-A12. The basis for alignment error compensation has been also established. Tooth contact and stress analyses demonstrate the advantages and limitations of the proposed method, making it suitable for applications with higher power demands for the drive side than for the coast side.