Gear Machining v1

AdvantEdge: How it Works | HPC Client | Gear Machining | Band Sawing & Keyway BroachingCase Studies | System Requirements

Both cylindrical and spiral bevel gear machining can be studied through cylindrical hobbing, face hobbing and face milling processes. Cylindrical hobbing allows users to input workpiece dimension and process parameters using industry standard terminology.

The workpiece will be positioned relative to the tool and an in-cut Boolean profile generated based on the imported tool solid model (STEP) profile. The tool and workpiece motion is then combined with the physics-based solver and adaptive remeshing algorithms for simulation of the gear machining process. Simulation results are easily analyzed and collected using machining specific results analysis and report generation.

The spiral bevel gears capability included the ability to simulate both single and continuous processes with both generating and non-generating motions.



  • Simulate and analyze and cutting process and chip formation
  • Reduce manufacturing costs through tool life and material remove rate improvements
  • Improve gear quality by identifying chip formation problems and the heat, stress added during machining
  • Increase development ROI by reducing engineering effort and trial-and-error prototype testing

Due to the significant cost and difficulty of studying and understanding gear machining processes through experimental methods, the ability to virtually model and simulate this process is expected to be an important innovation for the industry. 

  • Analyze Cutting Processes (temperature, strain, stress, force, chip shape)
  • Reduce Manufacturing Costs
    • Analyze tool failure and chip formation,
    • Increase material removal rates
    • Increase tool life
  • Improve Gear Quality
    • Analyze gear residual stress indicators
    • Identify potential chip flow complications
    • Reduce tool and gear tool deflection
  • Increase Development ROI
    • Reduce engineering effort
    • Reduce trail-and-error prototype testing
    • Reduce time to market

In order to generate accurate results Third Wave Systems created independent models and tests for gear machining verification. The testing utilized the user interface setup information to compare the generated initial geometry, cutting tool and blank positioning, process kinematics, gear in-cut Boolean and automatically calculated meshing parameters. 

Accurately predicting what will occur in reality is fundamental to the value of AdvantEdge simulations.  Validation of our simulations for gear machining was done through comparison with a large number of experimental cutting tests. The cutting tests generated force data, chips and provided initial indications of tool wear.  The data was generated by TWS engineers at the corporate Testing & Validation Center in Minneapolis, Minnesota. 

Gear Machining Validation Photos

Gear Machining_Verification Photos



  • Spiral Bevel Gear Machining: New Release Features.
    July 26, 2017. 8:30-9:00am CST.


To learn more about Third Wave Systems products and services or to setup a live web demonstration for Production Module, contact us at, or +1-952-832-5515.