Straight bevel gears for a fraction of the cost

Straight bevel gear cutting on Phoenix? II machines in 2006 was the beginning of a new arising popularity of straight bevel gear applications. This new demand led in turn to a series of developments which were aimed at higher productivity and state of the art software tools. The result is not only a multiple times faster cutting process of gear sets which have improved operating properties but also higher production stability due to closed loop network with Gleason CMM and automatic calculation of corrections.

The new Gleason straight bevel gear system offers:

? Tooth Contact Analysis (TCA) and nominal flank surface calculation (Figure 1)

?  Closed loop networking  including corrections from measurement

? High speed dry cutting with two or three face ground and coated carbide blades

? Flexible, peripheral cutter head system CONIFLEX? Plus utilising stick blades (Figure 2)

? Short setup times

? Fast “Roll Only Cycle” for generated parts

? Non-generated version of CONIFLEX ring gears

? Peripheral cutter build device

The new CONIFLEX system delivers better performing straight bevel gears with a new manufacturing process that reduced the total cost of ownership by a significant factor. In many cases, one Phoenix- CONIFLEX? Plus installation can replace more than 10 mechanical machines, yet, the same Phoenix machine can be utilised for regular spiral bevel and hypoid gear cutting without any limitations. In summary, the advantages of the new Gleason straight bevel gear package are:

? Cutting times reduced to a third of the traditional wet cutting process (Figure 3)

? Further cutting time reduction of 5% to 15% in combination with non-generated ring gear

? 75% reduced energy consumption

? Environmentally friendly process without any cutting oil

? High part quality

? Optimisation of tooth contact

? Standard versatile Phoenix Machine

? Versatility due to standard PENTAC?  blades and re-sharpening with standard Gleason equipment

CONIFLEX is believed to be only true straight bevel gear cutting method in the market. It used to be limited to old mechanical machines and wet cutting with hand calculated corrections. Now, the new Gleason CONIFLEX is a modern, highly economical manufacturing process in a modern industrial environment.

The technical paper on CONIFLEX? Plus covers the specifics of all new straight bevel developments; it shows examples and features several tables and diagrams of the new, revolutionary manufacturing process. If you wish to request a full copy of this technical paper, please e-mail Gleason Corporation at rewanow@gleason.com