Bevel gears are employed in the transmission of motion and torque via non-parallel shafts. When higher strength and lower noise is the objective, spiral bevel gears are used because of their higher tooth contact ratio. Face milling and face hobbing are among the most significant operations for the machining of hypoid and spiral bevel gears due to their high productivity. Although the optimization of these processes is crucial for the production of high-quality gears and the minimization of the total manufacturing cost, there are not many studies reported in this research area, owing to the high complexity of process kinematics. Furthermore, several kinematic variations of the two methods are applied in industry and their results depend highly on the cutting tool geometry. A novel simulation model integrated into a commercial CAD platform has been developed. The model achieves the 3D kinematic simulation of both face milling and face hobbing processes, generating the undeformed solid chip geometry as well as the simulated tooth solid geometry of a spiral bevel gear pinion and a spiral bevel gear wheel as an output. The simulation approach has two main purposes. First, is the optimization of the process through the investigation of the effect of cutting parameters on the quality of the obtained solid tooth flank geometry and second, is the calculation of cutting forces with the use of the obtained solid chip geometries. Aiming towards the validation of the model, the resulted tooth flank geometry is compared with the theoretical tooth exported from a well-established commercial gear calculation and design software and it is verified by means of a novel validation algorithm, also developed as part of this study. This paper focuses on the presentation of the kinematic simulation methodology and the simulation results for the face milling process. An insight into the validation model is provided and validation results are also presented. Finally, a sample investigation of the effect of generating feed rate on the produced gear geometry is conducted with the use of both algorithms.

锥齿轮用于通过非平行轴传递运动和扭矩。当目标是更高的强度和更低的噪音时，由于其较高的齿接触比而使用螺旋锥齿轮。端面铣削和滚齿由于其高生产率而成为加工准双曲面齿轮和螺旋锥齿轮的最重要操作之一。尽管这些过程的优化对于高质量齿轮的生产和最小化总制造成本至关重要，但是由于过程运动学的高度复杂性，该研究领域的研究报道很少。此外，这两种方法的几种运动学变化已在工业中应用，其结果在很大程度上取决于切削刀具的几何形状。已经开发出一种集成到商业CAD平台中的新颖仿真模型。该模型实现了端面铣削和滚齿加工的3D运动学仿真，生成未变形的实体切屑几何形状以及螺旋锥齿轮小齿轮和螺旋锥齿轮的模拟齿实体几何形状作为输出。模拟方法有两个主要目的。首先，是通过研究切削参数对所获得的实心齿侧面几何形状的质量的影响来优化工艺，其次是利用所获得的实心切屑几何形状来计算切削力。为了验证模型，将得到的齿面几何形状与从成熟的商用齿轮计算和设计软件输出的理论齿进行比较，并通过一种新颖的验证算法对其进行验证，该算法也是本研究的一部分。本文重点介绍了运动学仿真方法以及端面铣削过程的仿真结果。提供了对验证模型的见解，还提供了验证结果。最后，使用这两种算法对进给速度对所产生的齿轮几何形状的影响进行了样本研究。提供了对验证模型的见解，还提供了验证结果。最后，使用这两种算法对进给速度对所产生的齿轮几何形状的影响进行了样本研究。提供了对验证模型的见解，还提供了验证结果。最后，使用这两种算法对进给速度对所产生的齿轮几何形状的影响进行了样本研究。