HyGEARS™ V 4.0
Cylindrical / Bevel / Hypoid Gear Design, Analysis and Production Control Software
                                                          with 3, 4, 5Axis CnC Gear Manufacturing

 5 Axis CnC Machine Pre-Processor

Any gear design that is targeted for cutting on a conventional gear cutting machine can be cut on a 5Axis CnC machine. All CnC machine architectures are supported.

The part programs created by HyGEARS offer several cutting cycles and can use the following tools:

  • Face Mill cutter (Gleason or other); PTR-Tec (www.PTR-TEC.de) makes integral Face Mill cutters from 1" to 6" which are well suited to 5 Axis CnC machines;
  • Coniflex dish type cutters;
  • CoSIMT (or Conical Side Milling Tool), such as the InvoMilling tools from Sandvik, or the PMR tools from PTR-Tec;
  • End Mill cutter; which can be conical or cylindrical; HyGEARS uses the side of the End Mill to cut the tooth flank; if there is sufficient edge radius, the fillet can be cut at the same time; if not, a cutting cycle is dedicated to the fillet using the End Mill ;
  • Ball Mill cutter; HyGEARS uses the lower part of the Ball Mill to cut the tooth flank to avoid shank interference; another cutting cycle is dedicated to the fillet using the Ball Mill.
Cutting times vary with the tool used. In order of performance, we have:
  • Face Mill / Coniflex cutters
  • CoSIMT
  • End Mill
  • Ball Mill

The following links show some animated simulations of CnC tool paths for several gear types, on AC and BC type machines.  HyGEARS converts the machining motions to part programs for the selected controller output for direct download to a 5 Axis CnC machine. 

 Spur gears  End Mill    - BC machine  CoSIMT - BC machine 
 Coniflex gears  Dish cutter - BC machine  CoSIMT - BC machine
 Face gears  CoSIMT   - AC machine  CoSIMT - BC machine
 Face Milled Hypoid  Face Mill   - AC machine  CoSIMT - BC machine
 Face Hobbed Hypoid     CoSIMT - BC machine