This article presents a summary of all factors that contribute to efficient and economical high-speed cutting of bevel and hypoid gears. The influence of factors like tool material, tool coating, work gear blank material, tool geometry and speeds and feeds are discussed, and recommendations are given for optimal parameters. A diagram showing graphs that explain the dependencies between cost per part and two- or three-face-coated blades is introduced. In addition to tool life graphics and typical photos of worn and damaged carbide blades, two possibilities to add material to an existing blade point for increased tool life are shown. This article does not present the solutions for all possible problems of every existing high-speed dry cutting installation, but it gives a guideline that can help find ways to improve and optimize individual cutting scenarios.
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