Research on CNC machining technology of straight bevel gears based on hypocycloids

Bevel gear transmission is characterized by strong load capacity, stable transmission, and compact structure. It is a key component in power transmission systems for vehicles, ships, machine tools, oil drilling equipment, aerospace, and other industries. Amid the rapid development of electrification, gears remain indispensable in mechanical systems. Bevel gears are typically machined using gear shaping or dual-cutter disk milling methods, which are efficient but require specialized machines, resulting in high procurement costs. These methods are also unsuitable for machining large gears or small-batch production. Inspired by the linear mechanism of the internal pendulum, this paper proposes a CNC machining method for straight bevel gears based on hypocycloid mechanisms. By leveraging the straight-line properties of hypocycloid motion, straight bevel gears are machined via milling or grinding on a five-axis machining center using the end-face hobbing method. This method transforms the traditional non-continuous machining into continuous indexing machining and enables CNC machining on a general five-axis machining center. This approach reduces the cost of specialized equipment and improves the efficiency of straight bevel gear manufacturing.