1. Gleason Gear Cutter
2. Gear Design Lost Saga

Input Parameters Gear type - according to the position of root and head cone Gear ratio and tooth numbers Pressure angle (the angle of tool profile) α t Helix angle β m Axis angle Σ Tangential module on outer cone met (for metric calculation) Tangential Diametral Pitch on outer cone Pet (for English units) Note: Module and Diametral Pitch are reciprocal values. Gleason is your global source for the industry’s most complete line of cylindrical gear-making tools. PM-HSS Hobs Gleason hobs significantly improve the productivity of machining gears from small to large modules, roughing to finishing, as well as soft cutting or skiving operations. Figure 2 shows a Gleason No. 2A CONIFLEX generator with the interlocking cutters engaged in a slot of a ring gear. In the case of a 20° pressure angle system and a tilt angle of 20° for each cutter, the planes of the cutter disks would generate flank surfaces that consist of precise spherical involutes.

At this year’s Motion + Power Technology Expo(MPT) in Detroit, MI, USA, Gleason Corporation will showcase an array of new design, manufacturing, and inspection technologies for cylindrical and bevel gears. Highlights include: Closed Loop Hard Finishing Cell with integrated In-Process Laser Measuring, Gear Noise Detection and Analysis Systems, new Chamfer Hobbing Technology, and the latest release of KISSsoft Transmission Design Software.

Gleason will demonstrate the current KISSsoft Release 2019 with numerous new highlights: Among other things, “KISSdesign”, an instrument that allows intuitive concept design at system level, is now available. SKF and KISSsoft have also created a new interface to simplify the gear development process. This interface enables engineers to perform calculations using the latest bearing data from SKF via a direct connection to the SKF cloud. The manufacturability for Power Skiving can now also be evaluated in KISSsoft. After generating a special report with workpiece and tool data, this report can be transferred to Gleason if required, which makes data exchange between the designer and the tool supplier much easier and less error-prone.
The interface between GEMS and KISSsoft provides an exchange of gear and system information between the two software packages. This allows the user to realistically evaluate and optimize every type of bevel and hypoid gear – with a Closed Loop between the design and manufacturing software.

Gleason Gear Cutter

Closed Loop: High Accuracy and Excellent Surface Finish with the Genesis 260GX Threaded Wheel Grinding Machine with Automation and integrated 100% In-Process Laser Inspection

Now, Gleason takes hard finishing of high-quality gears to the next level: featuring the latest 260GX Threaded Wheel Grinding Machine with twist-controlled and polish grinding, software-guided single tool setup and “Closed Loop readiness” with a multi-functional automation system including Gleason’s new GRSL Gear Roll Testing System with laser technology for fast and reliable 100% in-process gear inspection. The completely integrated solution interfaces directly with the grinding machine for automatic correction of tooth size, profile and lead angle as well as lead crowning. This world first closed loop manufacturing concept will show you the wealth of options of integrated manufacturing.

The new GRSL Gear Rolling System with laser technology enhances gear measuring and sets a new standard for throughput where high speed, high volume testing is required. This compact gear inspection unit provides both double flank roll testing as well as analytical index and involute measurement as well as a new lead measurement feature on all teeth for full, analytical and functional in-process inspection. The GRSL can be employed either as stand-alone or fully integrated, automated solution. Real time analytics and process trend analysis are clearly visible over the production run, allowing for automatic Closed Loop corrections on Gleason process equipment. Users can also sort by defect so gears for rework or scrap are tracked by characteristic.

Gear Noise Detection and Analysis with 300GMSL Multi-Sensor Technology
The latest 300GMSL Gear Metrology System combines standard tactile probing methods for cylindrical and bevel gears with the power of non-contact laser scanning of tooth flank form. The integration of laser scanning and associated 3D graphics with CAD interface considerably expands both the functionality and the range of applications for this machine platform and is ideally suited for thorough gear analysis and development. Achieving a more complete analysis of process variable changes becomes much more intuitive with the high-resolution topographical surface mapping capability. A new host of tools for the detection and analysis of gear noise makes the 300GMSL an ideal solution for addressing this critical factor in today’s eDrive transmissions. The 300GMSL is “Closed Loop ready” to network to many of Gleason’s Hard Finishing Machines.

Integrated Chamfer Hobbing on the New Genesis 160HCD Hobbing Machine
The latest edition to the Genesis® Gear Hobbing Machine family combines the state-of-the-art technology in gear hobbing with newly developed Chamfer Hobbing, which produces precise chamfers according to customer specifications, while minimizing tool cost-per-piece. Gleason will also demonstrate live the seamless integration of tool and machine workflows, reducing manual data input and minimizing input errors, tracking every aspect of tool information from supplier to machine, to crib, to sharpening, to end of tool life.

New Workholding Solutions
Gleason presents two new workholding products: The new generation of expanding and contracting Hydraulic Production Arbors offers a host of benefits for many bore and shank clamping applications for cylindrical gears of all types and many bevel gears. New Modular Standard Workholding puts the performance benefits of Gleason’s latest quick-change workholding solutions into a system of standard, interchangeable modules. Available for cylindrical gear bores ranging from 18 to 100 mm in diameter, and easily applied to all types of Gleason and other gear equipment producers’ machines.

Gleason Diamond Dressing Tools for Improved Performance
Gleason diamond dressing tools improve performance on machines of various manufacturers. These diamond-plated tools can be re-plated multiple times to extend tool life and maintain the highest precision. With 30+ years of experience in diamond plating technology Gleason can address every gear related dressing solution in the market including solutions for polished surfaces or asymmetrical gears. Tools can be equipped with RFID, barcode or QR technology to integrate in 4.0 tool management environments.

Innovative Service Offerings
Gleason will present a host of new service offerings including: The Gleason SPN Program (Safety-Productivity-Networking) is a simple and economic field service alternative to a complete re-control of old Siemens 840D pl and many models of Gleason Metrology Inspection machines. With the SPN Upgrade, machine owners regain system safety with updated virus and hacker protection, secure spare parts availability, and extend the control’s functionalities beyond its former capabilities. Gleason Fingerprint diagnoses machine problems and potentially prevents downtime of installations. Gleason will showcase their capabilities via applications in the cloud and edge computer to serve varied customer requirements. Tool-to-Machine communication adds intelligence to tool management, reduces manual data input and minimizes input errors. It provides data and methods to track every aspect of tool information from supplier to machine, to crib, to sharpening, to end of tool life. The new Gleason Academy platform is continuously growing in content including theoretical training classes and operator training in tutorial style. Our trainers will show you how easy it is to get educated without travel, related expenses and the loss of time.

Gleason
www.gleason.com

Changzhou Baoxin Gleason Spiral Bevel Gears Calculation

Gear Design Lost Saga

A spiral bevel gear is one with a spiral tooth flank as in Figure 1. The spiral is generally consistent with the curve of a cutter with the diameter dc. The spiral angle β is the angle between a generatrix element of the pitch cone and the tooth flank. The spiral angle just at the tooth flank center is called the mean spiral angle βm. In practice, the term spiral angle refers to the mean spiral angle.

Fig.1 Spiral Bevel Gear (Left-hand)

All equations in Table 2 are specific to the manufacturing method of Spread Blade or of Single Side from Gleason. If a gear is not cut per the Gleason system, the equations will be different from these.

The tooth profile of a Gleason spiral bevel gear shown here has the tooth depth h = 1.888m; tip and root clearance c = 0.188m; and working depth hw = 1.700m. These Gleason spiral bevel gears belong to a stub gear system. This is applicable to gears with modules m > 2.1.

Table 1.8 shows the minimum number of teeth to avoid undercut in the Gleason system with shaft angle Σ = 90° and pressure angle αn = 20°.

Table 1.8 The minimum numbers of teeth to prevent undercut β=35°

If the number of teeth is less than 12, Table 1.9 is used to determine the gear sizes.

Table 1.9 Dimentions for pinions with number of teeth less than 12

Table 2 shows the calculations for spiral bevel gears in the Gleason system

Table 2 The calculations for spiral bevel gears in the Gleason system

No.	Item	Symbol	Formula	Example
				Pinion (1)	Gesr (2)
1	Shaft angle	∑	Set Value	90 deg
2	Module	m		3
3	Normal pressure angle	αn		20 deg
4	Mean spiral angle	βm		35 deg
5	Number of teeth and spiral hand	z		20 (L)	40 (R)
6	Transverse pressure angle	αt	23.95680
7	Reference diameter	d	zm	60	120
8	Reference cone angle	σ1 σ2	26.56505 deg	63.43495 deg
9	Cone distance	R	67.08204
10	Facewidth	b	It should be less than 0.3R or 10m	20
11	Addendum	ha1 ha2	3.4275	1.6725
12	Dedendum	hf	1.888m – ha	2.2365	3.9915
13	Dedendum angle	θf	tan^-1( hf / R )	1.90952 deg	3.40519 deg
14	Addendum angle	θa1 θa2	θf2 θf1	29.97024 deg	1.90952 deg
15	Tip angle	σa	σ + θa	29.97024 deg	65.34447 deg
16	Root angle	σf	σ – θf	24.65553 deg	60.02976 deg
17	Tip diameter	da	d + 2ha cos σ	66.1313	121.4959
18	Pitch apex to crown	X	R cos σ – ha sin σ	58.4672	28.5041
19	Axial facewidth	Xb	17.3565	8.3479
20	Inner tip diameter	di	46.1140	85.1224

All equations in Table 2 are also applicable to Gleason bevel gears with any shaft angle. A spiral bevel gear set requires matching of hands; left-hand and right-hand as a pair.

(4) Gleason Zerol Bevel Gears
When the spiral angle bm = 0, the bevel gear is called a Zerol bevel gear. The calculation equations of Table 4.16 for Gleason straight bevel gears are applicable. They also should take care again of the rule of hands; left and right of a pair must be matched. Figure 4.13 is a left-hand Zerol bevel gear.

Fig. 1.3 Left-hand zerol bevel gear