Simulative optimization of continuous bevel gear manufacturing with special regard to effective tool angles

In recent years, extensive research has been carried out on the influence of tool and process design on tool wear for bevel gear cutting. However, due to the complex interactions between tool, gear and process design, an analytical analysis of the cutting process has proven difficult. In this paper, the influence of the tool design on tool wear in continuous bevel gear manufacturing is analyzed using both simulations and cutting trials. Initially, a theoretical analysis is performed using a manufacturing simulation and a method is derived to calculate the effective tool angles. Subsequently, the results of cutting trials using the same tool designs are presented and compared to the simulation results.