Face hobbing, a continuous indexing and double-flank cutting process, has become the leading method for manufacturing spiral bevel gears and hypoid gears because of its ability to support high productivity and precision. The method is unsuitable for cutting straight bevel gears, however, because it generates extended epicycloidal flanks. Instead, this paper proposes a method for fabricating straight bevel gears using a virtual hypocycloidal straight-line mechanism in which setting the radius of the rolling circle to equal half the radius of the base circle yields straight lines. This property can then be exploited to cut straight flanks on bevel gears. The mathematical model of a straight bevel gear is developed based on a universal face-hobbing bevel gear generator comprising three parts: a cutter head, an imaginary generating gear, and the motion of the imaginary generating gear relative to the work gear. The proposed model is validated numerically using the generation of face-hobbed straight bevel gears without cutter tilt. The contact conditions of the designed gear pairs are confirmed using the ease-off topographic method and tooth contact analysis (TCA), whose results can then be used as a foundation for further flank modification.

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