Abstract
Asymmetrical gears have advantages in applications with a preferred load direction, such as automotive transmissions or wind turbines. The operational behavior of gears with asymmetrical profiles has already been thoroughly investigated. However, there are very few studies on the manufacturability of gears with asymmetric profiles regarding the possible interactions between pressure angle composition, tool and process design. In this report, the influence of asymmetrical profiles on the wear behavior of hobs is analyzed for the first time.For this purpose, eight different tool variants have been defined for an investigation on tool wear behavior based upon fly-cutting trials. These variants consist of two symmetric and four asymmetric variants. In addition, two asymmetric variants with additional protuberance have been defined. Tool performance decreased within the fly-cutting trials with a low pressure angle on the leading flank and also in the presence of a protuberance. As the pressure angle increases on the leading flank, an increase on the tool life was observed.
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