Bevel gears are widely used in various industrial applications, such as automotive, aerospace, and marine industries, due to their ability to transfer power between non-parallel shafts. The conventional manufacturing of bevel gears involves several time-consuming and costly processes, including gear blank preparation, gear cutting, and gear finishing. The increasing demands on gear components regarding increasing power density, reducing installation space, reducing weight, and increasing efficiency are also reflected in the design of gear components. The reduction of installation space and weight as well as the increase in power density often leads to an optimized wheel body design that interacts with the gearing in terms of load capacity and stiffness. This leads to an increase in the required geometric degrees of freedom (DOFs). Due to the resulting complex wheel body shapes and different production-related effects, production-related geometry adjustments may also be necessary. Tools for evaluating the gearing in combination with the wheel body shape and its influences nowadays form the basis for unlocking the holistic optimization potential of transmission components. 

Standardized methods, like AGMA 2001-D04 or ISO 6336 for the calculation of the load carrying capacities of gears are intentionally conservative to ensure broad applicability in industrial practice. However, new applications and higher requirements often demand more detailed design calculations nowadays; for example: long operating lives in wind power gearboxes or fewer gear stages and higher speeds in e-mobility applications result in higher load cycles per tooth in a gearbox.