Obtaining the geometry and 5-axis machining paths for the manufacture of spiral bevel gear

Abstract This study introduces a flexible methodology for the design and manufacturing of spiral bevel gears using five-axis NC machines, overcoming the rigidity of traditional methods. The innovation lies in the definition of customizable input parameters combined with the application of the Darboux trihedron to generate accurate and efficient toolpaths. The methodology integrates geometry generation, CAD modelling, and preliminary validation through additive manufacturing to improve collision detection and ensure feasibility. The experimental results, conducted on a five-axis machining centre, demonstrated the feasibility and high accuracy of the proposed approach. The solution enables the manufacturing of customized gears in different sizes, optimizes NC code generation by reducing code volume without compromising precision, and provides a robust alternative to commercial black-box software, offering greater control and adaptability for industrial applications.