Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors

In this paper, a five-axis machining process is analyzed for large spiral-bevel gears, an interesting process for one-of-kind manufacturing. The work is focused on large sized spiral bevel gears manufacturing using universal multitasking machines or five-axis milling centers. Different machining strategies, toolpath patterns, and parameters are tested for both gear roughing and finishing operations. Machining time, tools' wear, and gear surface are analyzed in order to determine which are the best strategies and parameters for large modulus gear manufacturing on universal machines. The case study results are discussed in the last section, showing the capacity of a universal five-axis milling for this niche. Special attention was paid to the possible affectations of the metal surfaces, since gear durability is very sensitive to thermo-mechanical damage, affected layers, and flank gear surface state.