A rack bar blank material includes a rack portion configured to mesh with a pinion in an end side of a hollow shaft material in an axial direction, and an end portion which is provided closer to the end side of the hollow shaft material than the rack portion. The end portion has a diameter which is larger than that of a minimum circle embracing a section of the rack portion which is perpendicular to the axial direction and which is equal to that of a shaft portion at the other end side of the shaft material in the axial direction.

A gear machining method includes: roughing a workpiece while causing a cylindrical hob cutter to rotate in synchronization with a rotation of the workpiece such that a cutting allowance remains; and finishing by cutting off the cutting allowance remaining on the workpiece on which the roughing has been performed during the roughing to form a desired gear shape by feeding a skiving cutter relatively to the workpiece in the rotation axis direction of the workpiece while causing the skiving cutter to rotate in synchronization with the rotation of the workpiece.

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 cutter build and truing machine (22) comprising a mechanism (52, 54) to position cutting blades (98) by moving the blades in either direction in a mounting slot (96) of a cutter head (94). The machine further includes a torque spindle (62) and driver (66) to automatically tighten or loosen clamp bolts (102).

The present disclosure shows a method for gear cutting a workpiece on a machine tool that comprises a workpiece holder drivable about an axis of rotation and at least one tool holder drivable about an axis of rotation, wherein for the gear cutting operation a tool with a circular cylindrical shell surface is used, which with its shell surface is guided along a tooth flank of the workpiece tangentially to the target contour to be produced. According to an embodiment of the present disclosure it is provided that the tangential alignment of the shell surface relative to the target contour to be produced is achieved by positioning the tool along a first linear axis and by a rotary position of the workpiece about its axis of rotation.

The present disclosure shows a method for gear cutting a workpiece on a machine tool that comprises a workpiece holder drivable about an axis of rotation and at least one tool holder drivable about an axis of rotation, wherein for the gear cutting operation a tool with a circular cylindrical shell surface is used, which with its shell surface is guided along a tooth flank of the workpiece tangentially to the target contour to be produced. According to an embodiment of the present disclosure it is provided that the tangential alignment of the shell surface relative to the target contour to be produced is achieved by positioning the tool along a first linear axis and by a rotary position of the workpiece about its axis of rotation.

A method wherein a cutting or grinding chamfering tool (25) is guided along the face width of a gear (12, 23, 52) through one tooth slot (8) (e.g. from heel to toe) while it contacts the topland corners (10, 1 1) of the respective concave and convex tooth flanks of adjacent teeth (2, 4). The tool moves to an index position, the gear is indexed to the next tooth slot position and the tool moves through the tooth slot (e.g. from the toe to the heel). The cycle is repeated until all topland corners are chamfered.

A method wherein a cutting or grinding chamfering tool (25) is guided along the face width of a gear (12, 23, 52) through one tooth slot (8) (e.g. from heel to toe) while it contacts the topland corners (10, 1 1) of the respective concave and convex tooth flanks of adjacent teeth (2, 4). The tool moves to an index position, the gear is indexed to the next tooth slot position and the tool moves through the tooth slot (e.g. from the toe to the heel). The cycle is repeated until all topland corners are chamfered.

A rotating cutting tool to cut asymmetrical teeth in a gearwheel in which each tooth (21) has an active flank (A) with a convex profile meshing with the profile of a tooth of an opposing gearwheel meshing with the gearwheel and a secondary concave flank (S), provided with teeth (11) on a generally helical path which extends from one side to the other with respect to a median cross-section (M-M) of the tool which is intended to be intersected by the radius Rp of the gearwheel which is at right angles to the axis of rotation of the tool working on the gearwheel to cut its teeth. The helical teeth have a first flank (CA) which is intended to cut the said active flank (A) of the gearwheel teeth and a second flank (CS) intended to cut the secondary flank (S), the pitch (P1) between the first flank (CA) of the helical teeth being constant and the pitch (P2) of the second flank of the teeth being smaller than the pitch (P1).

A method for manufacturing a sintered gear comprising the steps of: preparing a cylindrical green compact; gear-cutting the green compact with a hob; and sintering the gear-hobbed green compact, wherein the hob is such that a ratio of a number of cutting edges thereof per round to a number of starts thereof exceeds 8.