Tutorial download here...

    High Ratio Hypoid software is similar to the previously released Hypoid software but adjusted for higher hypoid offset and small number of teeth on the pinion.

This 3d modeling program works in MS Excel. Input gear data into Excel and run an attached VBA macro to generate 3d igs surfaces of the gear and pinion teeth. Works with all existing CAD programs. Download output examples:

- Gear tooth flank with lead and profile modification for better contact pattern: g1, g2 

- Working flanks of the pinion modified for correct tooth contact pattern and correctly generated root undercuts: 1, 2, 3, 4.

The Excel generated surfaces are used to make accurate 3d CAD model of High Ratio Hypoid gear in SolidWorks:

Download STEP sample here...

Tooth contact pattern can be checked on our TCA software or in CAD by using interference option a shown below:

More interference shows larger size of the immediate tooth contact.

When interference increases the tooth contact spreads on all the teeth. This software allows the gear set to be specifically designed with localized tooth contact. 

This program is working as a gear generator. It uses the gear tooth as the cutting tool that generates the pinion tooth in rolling motion identical to a gear cutting machine. This method provides the best gear tooth geometry with 100% conjugated action, which is impossible to achieve on Gleason generating machines. The contact patter localization is added to the gear or to the pinion or to both if needed in order to compensate for possible misalignments in assembly. The gear face angle can be designed to 90 degrees (flat face) for cost reduction, like on this sample. The face angle of the pinion can be 0 (cylinder). This program can deliver position of the vector axis of the cutter head during the tooth generating process. The position of the cutter head vector is used in programming of a 5-axis CNC machine to cut the gear and the pinion if a cutter head is used for cutting.

High Ratio Hypoid (HRH) gears look very similar to worm face gears. The advantage of HRH gear is simplicity of the face gear cutting. The gear shown on this web site is cut by indexing of a cutter head (fly cutter) from tooth to tooth without generating motion. This method also called FORMATE by Gleason. The advantage of FORMATE method is that it does not need a Gleason gear generating machine. The manufacturing disadvantage of HRH compare to worm face gear is variable pitch on the pinion, which requires more CNC programming.     

 There are other opportunities with of this program. This gear in this program is the imaginary crown gear that is used in Gleason CAGE and Klingelnberg Kimos software for simulation of the gear cutting. In other words, this program simulates Gleason or Klingelenberg spiral bevel gear generating machine by using the gear tooth as a cutting tool. With correct numbers entered into this Excel program it will generate a 3d CAD surface of the gear flanks and the undercut surfaces exactly identical to the gear in real production on Gleason of Klingelnberg generators. The resulting gears can be examined on tooth contact using our TCA software. 

More CAD gear models here...

Numbers of the dimension lines point to the input lines in Excel.

Input all the data you know and the program suggests the remaining input data for better design.

This program is based on a generating method: The gear tooth geometry is simplified for low manufacturing cost based on the cutting methods available. For example the current gear sample is cut by forming (fly cutter), not generating. The program uses the gear tooth model in order to generate the pinion tooth by simulation of machining of the pinion by the gear tooth acting as a cutter head. This method results in 100% conjugated teeth.