A bevel gear set and a method of manufacturing the same are provided. The bevel gear set may include a first bevel gear and a second bevel gear. The first and second bevel gears may be spiral bevel gears or hypoid spiral bevel gears. The first and second bevel gears may each have a gear tooth surface having a plurality of teeth formed thereon, such that the teeth of the first bevel gear and the teeth of the second bevel gear are configured to engage in a meshing engagement. The teeth are machined onto the respective gear tooth surface via a face milling process. Each tooth includes a tooth top, a plurality of meshing surfaces, and at least one chamfer. The chamfer may be formed at an abutment edge disposed between the tooth top and a respective meshing surface via a brushing process directly following the machining of the teeth.

A method for manufacturing a hypoid gear includes: a tooth cutting step of machining a shape of a tooth of the hypoid gear; a surface treatment step of forming a third intermediary gear provided with a hardened layer on a surface of the tooth; a lapping step of machining the third intermediary gear using an abrasive particle having a diameter of 14 μm or less to form a fourth intermediary gear; and a shot peening step of spraying a particle having a diameter of 160 μm or less onto the fourth intermediary gear.

A method for manufacturing a hypoid gear includes: a tooth cutting step of machining a shape of a tooth of the hypoid gear; a surface treatment step of forming a third intermediary gear provided with a hardened layer on a surface of the tooth; a lapping step of machining the third intermediary gear using an abrasive particle having a diameter of 14 μm or less to form a fourth intermediary gear; and a shot peening step of spraying a particle having a diameter of 160 μm or less onto the fourth intermediary gear.

A process for forming a finished spiral bevel gear includes forging a blank to form a forging having near net-shaped spiral bevel teeth, machining the forging, coining the forging to form a coined spiral bevel gear with net-shaped spiral bevel gear teeth; heat treating the coined spiral bevel and finishing the heat treated, coined spiral bevel gear without machining the net-shaped spiral bevel gear teeth in a machining operation that forms chips.

A mutual-lapping device and mutual-lapping method for improving processing precision based on the principle of error averaging is proposed. The device including driving friction wheel, driving belt pulley, transmission belt A, connecting rod A, rotation shaft segment A, multi-ball sleeve, mutual-lapping gear A, tension spring, driven friction wheel, pendulum bar of the driven friction wheel, driven belt pulley, transmission belt B, connecting rod B, pressure spring of tensioning pulley, tensioner mechanism, rotation shaft segment B and mutual-lapping gear B. By mutual lapping the high-precision gears, not only the pitch deviation, tooth profile deviation, helix deviation and runout can be reduced synchronously, but also the machining cost is low. Meanwhile, the effect of improving pitch accuracy, profile accuracy, helix accuracy and runout accuracy and reducing surface roughness is remarkable.

A mutual-lapping device and mutual-lapping method for improving processing precision based on the principle of error averaging is proposed. The device including driving friction wheel, driving belt pulley, transmission belt A, connecting rod A, rotation shaft segment A, multi-ball sleeve, mutual-lapping gear A, tension spring, driven friction wheel, pendulum bar of the driven friction wheel, driven belt pulley, transmission belt B, connecting rod B, pressure spring of tensioning pulley, tensioner mechanism, rotation shaft segment B and mutual-lapping gear B. By mutual lapping the high-precision gears, not only the pitch deviation, tooth profile deviation, helix deviation and runout can be reduced synchronously, but also the machining cost is low. Meanwhile, the effect of improving pitch accuracy, profile accuracy, helix accuracy and runout accuracy and reducing surface roughness is remarkable.

A process for forming a finished spiral bevel gear includes forging a blank to form a forging having near net-shaped spiral bevel teeth, machining the forging, coining the forging to form a coined spiral bevel gear with net-shaped spiral bevel gear teeth; heat treating the coined spiral bevel and finishing the heat treated, coined spiral bevel gear without machining the net-shaped spiral bevel gear teeth in a machining operation that forms chips.

A method that includes: providing a blank; heating the blank; forging the heated blank to form a forged gear having a plurality of spiral bevel gear teeth; machining the forged gear to a predetermined thickness while locating off of the plurality of gear teeth to form a green machined forged gear; rotationally and axially engaging a die to the gear teeth of the green machined forged gear to induce plastic flow in the gear teeth to form an intermediate gear in which the plurality of gear teeth conform to a predetermined tooth form; heat-treating the intermediate gear to form a hardened intermediate gear; and lapping the plurality of gear teeth of the hardened intermediate gear with a spiral bevel pinion gear; wherein the plurality of gear teeth are not machined in a chip-producing machining operation before the plurality of gear teeth are lapped.

A mutual-lapping device and mutual-lapping method for improving processing precision based on the principle of error averaging is proposed. The device including driving friction wheel, driving belt pulley, transmission belt A, connecting rod A, rotation shaft segment A, multi-ball sleeve, mutual-lapping gear A, tension spring, driven friction wheel, pendulum bar of the driven friction wheel, driven belt pulley, transmission belt B, connecting rod B, pressure spring of tensioning pulley, tensioner mechanism, rotation shaft segment B and mutual-lapping gear B. By mutual lapping the high-precision gears, not only the pitch deviation, tooth profile deviation, helix deviation and runout can be reduced synchronously, but also the machining cost is low. Meanwhile, the effect of improving pitch accuracy, profile accuracy, helix accuracy and runout accuracy and reducing surface roughness is remarkable.

A mutual-lapping device and mutual-lapping method for improving processing precision based on the principle of error averaging is proposed. The device including driving friction wheel, driving belt pulley, transmission belt A, connecting rod A, rotation shaft segment A, multi-ball sleeve, mutual-lapping gear A, tension spring, driven friction wheel, pendulum bar of the driven friction wheel, driven belt pulley, transmission belt B, connecting rod B, pressure spring of tensioning pulley, tensioner mechanism, rotation shaft segment B and mutual-lapping gear B. By mutual lapping the high-precision gears, not only the pitch deviation, tooth profile deviation, helix deviation and runout can be reduced synchronously, but also the machining cost is low. Meanwhile, the effect of improving pitch accuracy, profile accuracy, helix accuracy and runout accuracy and reducing surface roughness is remarkable.