Mathematically precise tooth surface definition and contact analysis help to develop state-of-the-art straight bevel gears for many industrial applications. The new Coniflex-Plus manufacturing process utilizes high-speed dry cutting with production times per slot which are about twice compared to the fast Revacycle process.

An economical modernization program gives Designatronics' tried-and-true Gleason No. 102 Coniflex generators a new lease on life for fast, reliable production of smaller precision straight bevel gears.

The cutting process consists of either a roll only (only generating motion), a plunge only or a combination of plunging and rolling. The material removal and flank forming due to a pure generating motion is demonstrated in the simplified sketch in Figure 1 in four steps. In the start roll position (step 1), the cutter profile has not yet contacted the work. A rotation of the work around its axis (indicated by the rotation arrow) is coupled with a rotation of the cutter around the axis of the generating gear (indicated by the vertical arrow) and initiates a generating motion between the not-yet-existing tooth slot of the work and the cutter head (which symbolizes one tooth of the generating gear).

What are the manufacturing methods used to make bevel gears used in automotive differentials?