In this paper, a manufacturing method of the pinion member of large-sized skew bevel gears using a multi-axis
control and multi-tasking machine tool respecting an existing gear member is proposed. First, the tooth
surface forms of skew bevel gears are modeled. Next, the real tooth surfaces of the gear member are
measured using a coordinate measuring machine and the deviations between the real and theoretical tooth
surface forms are formalized using polynomial equations. It is possible to analyze the tooth contact pattern of
the skew bevel gears with respect to the deviations of the real and theoretical tooth surface forms by
expressing the deviations as polynomial equations. Further, the deviations of the tooth surface form of the
gear member are reflected in the analysis of the tooth contact pattern and transmission errors, and the tooth
surface form of the pinion member that has good performance mating with the existing gear member is
determined. Finally, the pinion member is manufactured by swarf cutting using a multi-axis control and
multitasking machine tool. Afterward, the real tooth surfaces of the manufactured pinion member are
measured using a coordinate measuring machine and the tooth surface form errors are detected. In addition,
the tooth contact pattern of the manufactured pinion member and existing gear member is compared with
those of tooth contact analysis. The results show that there is good agreement.

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