Bevel gear cutting on milling machine

Here's a general overview of the process:

1. Gear Design: Determine the gear specifications, including the number of teeth, pitch angle, and module or diametrical pitch.

2. Set-Up: Start by setting up the milling machine and aligning the gear blank. Ensure proper clamping and alignment to avoid errors in the final gear.

3. Tool Selection: Choose the appropriate cutter for bevel gears. This can be a specially designed bevel gear cutter or a form cutter that matches the gear tooth profile.

4. Tool Positioning: Position the cutter at the correct height, tilt, and rotation relative to the gear blank. This positioning will depend on the desired gear tooth geometry and the specific requirements of the gear design.

5. Cutting Process: Engage the cutter with the gear blank, taking care to achieve the desired depth and feed rate. The cutter may need to be indexed or repositioned multiple times to cut all the required teeth.

6. Checking Accuracy: Regularly check the gear dimensions and tooth profiles using specialized measuring tools to ensure they meet the required specifications. Adjustments may be necessary during the cutting process to achieve the desired accuracy.

7. Finishing: After cutting the teeth clean the gear to remove any rough edges or burrs. Heat treatment and other finishing processes may also be needed based on the application.

It's important to note that cutting bevel gears on a milling machine requires careful attention to detail and expertise in gear cutting. If you don't have the necessary experience or equipment, it's advisable to consult with a specialized gear manufacturer or machine shop.