Goal of this paper is to provide a mathematical model able to compute the tooth surfaces of a face hobbed hypoid gear drive and to show how this model can be useful in order to develop a computerized design of these gears. In detail, the steps necessary to build the model, which is based on the simulation of face nobbing cutting process, will be firstly discussed. Then, by implementing this model in a Fortran code, an efficient tool to generate the input for an advanced contact solver will be created allowing an accurate face hobbed gear performance analysis which includes contact analysis and stress calculation.
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