A Straight Bevel Gear Generated by Copying with a Disk Tool

A kind of bevel gear with straight teeth generated by copying with a disk tool (milling cutter or grinding wheel) is considered. Toothing process in such a gear can be performed on common non-specialized machines. A design methodology, including transmission scheme and pinion cutting parameter selection, the conjugate gearwheel geometry and conjugate meshing calculation, gearwheel cutting parameter selection and the assessment of localized contact, is proposed. The gear features are characterized, in particular: the approximate nature of the meshing and, accordingly, the need to minimize the error of the teeth recoupling, the difference between the axoids and the initial surfaces, the need for a special angle selection of tooth downing and pinionshift. Methods for selection the cutting gear link parameters are given, that technically, demand contact between the generating surface and its feed path and the pinion bottom surface and the gearwheel reference surface. The theoretical possibility of ensuring 7th and 4th degree of accuracy in terms of smooth operation is demonstrated by the two calculation examples.