Unlike spur and helical gears, manufacturing of worm gears typically requires unique hob cutters for each design. The proposed method allows using the same hob cutter for different designs. The method is supported by tooth-cutting and tooth-contact simulation software. It has been applied to worm, worm face and high ratio hypoid gears. Using the method during design stage provides digital optimization of the tooth contact and prediction of allowable misalignments. The authors are presenting practical methodology and examples of using the software. In practice the proposed method can be described in simple words: Never buy a new worm hob cutter again if you already have a set of unified cutters and the software. Small and middle size companies will gain the most economical advantage if to use the proposed method and software. Larger companies can also benefit from the method by significant reduction of the product development time.
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