Obtaining the geometry and 5-axis machining paths for the manufacture of spiral bevel gear

This study proposes a methodology for the design and manufacturing of spiral bevel gears using five-axis NC machines. Unlike traditional methods, which are rigid and specific, this technique offers a flexible approach based on customizable input parameters. The process includes generating gear geometry using a point cloud, 3D modelling in software such as SolidWorks, and creating optimized machining toolpaths with tools like the Darboux trihedron to ensure precision and efficiency. Additionally, the use of additive manufacturing enables prior physical simulations, improving collision detection and validating the toolpaths.The experimental results, conducted on a five-axis machining center, demonstrate the feasibility and high accuracy of this methodology. The solution not only enables the manufacturing of customized gears in various sizes but also optimizes NC code generation, reducing code volume while maintaining precision. This represents a highly practical and robust alternative to conventional commercial tools, offering greater control and adaptability for industrial applications to effectively meet specific production needs.