Int J Adv Manuf Technol (2010) 49:1069–1077
DOI 10.1007/s00170-009-2466-0
ORIGINAL ARTICLE
Use of PLC module to control a rotary table to cut spiral
bevel gear with three-axis CNC milling
S. Mohsen Safavi & S. Saeed Mirian &
Reza Abedinzadeh & Mehdi Karimian
Received: 25 November 2008 / Accepted: 23 November 2009 / Published online: 5 January 2010
# Springer-Verlag London Limited 2009
Abstract CNC machining nowadays makes more use of
"Mechatronics" increasingly. Combining numerical control
with mechanic, electric, and data processing systems can
lead to new methods of production. In recent years, the
development of CNC has made it possible to perform
nonlinear correction motions for the cutting of spiral bevel
gears. In this paper, we attempt to manufacture the spiral
bevel gear using a three-axis CNC milling machine
interfaced with an additional PLC module based on
traditional discontinuous multicutting method accomplished
by using a universal milling machine interfaced with an
indexing work head. This research consists of (a) geometric
modeling of the spiral bevel gear, (b) simulating the
traditional and our new nontraditional method using a
CAD/CAE system, (c) process planning for CNC machin-
ing and PLC Programming, (d) experimental cuts with a
three-axis CNC milling machine were made to discover the
validity of the presented method. The results demonstrate
that invented experimental cutting method of SBGs not
only is less expensive than advanced CNC machining but
also produces gears in a shorter time in comparison with the
traditional cutting. Thereby, it is an economical method in
manufacturing of SBGs.
Keywords Gear manufacturing . Spiral bevel gear .
CAD/CAM/CAE . CNC . PLC . AC motor . Inverter .
Proximity sensors . Photoelectric sensors . Rotary encoder
S. M. Safavi : S. S. Mirian : R. Abedinzadeh (*) :
M. Karimian (*)
Mechanical Engineering Department,
Isfahan University of Technology,
Isfahan, Iran
e-mail: abedinzade@me.iut.ac.ir
e-mail m_karimian1973@yahoo.com
1 Introduction
Gears are important and precision mechanisms for indus-
trial machinery as a means for mechanical power or motion
transmission between parallel, intersecting and noninter-
secting cross-axis shafts. Although hidden from sight, gears
are one of the most important mechanical elements in our
civilization. They operate at almost unlimited speeds under
a wide variety of conditions. The machines and processes
that have been developed for producing gears are among
the most existing ingenious ones. Whether produced in
large or small quantities, in cell, or job shop batches, the
sequence of processes for gear manufacturing requires four
sets of operations [1]:
1. Blanking
2. Gear cutting
3. Heat treatment
4. Grinding
Depending on their type and application or required strength
and resistance, gears are manufactured by casting, extruding,
forging, powder metallurgy, plastic molding, gear rolling,
and machining. Among these processes, machining is more
frequently used for high-precise gears [2]. Among the
various types of gears, the spiral bevel gears (SBG) are
the most complex type and are used to transmit the
rotational motion between angularly crossed shafts.
SBGs have teeth curved longitudinally along the length
of the teeth. The main advantage of these gears over the
straight-toothed varieties lies in the fact that more teeth are
in contact at the same time because of the curve-shaped
contour of the teeth and so a smoother meshing action
between the mating pair is ensured [3]. The design and
manufacturing of spiral bevel gears is still a hot topic of
research that is vital for application of such gears in
1070
helicopter transmissions, motorcycle gears, reducers, and in
other branches of industry. As far as manufacturing is
concerned, the gears are machined by a special type of
machine tools, such as gear hobbing and shaping machines.
Recently, special CNC-based gear manufacturing machine
tools are used in industrial practice. This may be why literature
on gear manufacturing is sparse in the open research domain.
Recently, CNC-based gear manufacturing machine tools have
been developed and increasingly used in industrial practice.
However, their kinematic structure is still inherently different
from the industrial CNC milling machine, as the former is
designed for a special type of cutter.
Previous studies on gears have been mainly concerned
with the design and analysis of gears. The geometric
characteristics and design parameters of gears have been
studied [4–8]. Tsai and Chin [4] presented a mathematical
surface model for bevel gears (straight and SBGs) based on
basic gearing kinematcis and involute geometry along the
tangent planes. Later, this method was compared with
another model based on exact spherical involute curves by
Al-daccak et al. [5]. Shunmugan et al. [6, 7] presented a
different model, and its accuracy (compared with the spiral
bevel gear manufactured by special machine tools) was
verified in terms of nominal deviation.
For crown gears, a few results are available. Litvin and
Kim [8] suggested a generation method for an involute
curve from a modified base circle for a spur gear. Umeyama
[9] designed a standard profile at the pitch circle and a
modified profile at the top/bottom face gear with a
determination of the modification value for transmission
error of helical gear. Tamura et al. [10, 11] studied a point
contact model for a bevel gear using a flat surface tooth.
These studies are concerned with the generation of the tooth
profile for special gear machines, such as gear hobbing and
shaping machines, which are specially designed for
manufacturing gears. Suh et al. [12] investigated the
possibility of a sculptured surface-machining method for
the manufacture of spiral bevel gears and verified the
possibility by presenting tool-path generation using a four-
axis CNC milling machine interfaced with a rotary-tilt
table. A model-based inspection method for the spiral bevel
gears was also presented [13].
In this paper, we attempt to present a new manufacturing
procedure of SBGs by using a three-axis milling machine
interfaced with a PLC module which operates as an
indexing table. In terms of production rate, it is obvious
that this method will be lower than that of the special
machine tool. Other than production rate, this method is
advantageous in the following respects: (1) the convention-
al method requires a large investment for obtaining various
kinds of special machinery and cutters dedicated to a very
limited class of gears in terms of gear type, size, and
geometry; (2) by this method, various types of gears can be
Int J Adv Manuf Technol (2010) 49:1069–1077
manufactured with the industrial three-axis CNC milling
machine; (3) this method is more economical than using the
special machine tool. One of the main points which
separate our work from previous ones is developing an
automatic computer model in order to simulate the process
entirely and obtain machining parameter. All previous
studies have been engaged in calculating complicated
mathematical equations and designing geometric models.
In view of the above, special attention is given to
experimental tests rather than presenting geometrical or
mathematical model of SBGs. This is the first time that
mechatronic tools and a three-axis CNC milling machine
are being used simultaneously in manufacturing a special
gear and even a mechanical element.
2 Geometric specifications of the spiral bevel gears
Most of the time, the geometric parameters of a gear are
provided with an engineering drawing. Some parameters
(principal parameters) are required for defining the geom-
etry. Figure 1 shows module, spiral angle, and number of
teeth of gear. Table 1 summarizes these parameters
including relationships among parameters for the gear
which has been manufactured in our test. To calculate
these parameters, we have used “drive component devel-
opment software” called GearTrax.
The design of spiral bevel gear requires high-accuracy
mathematical calculations, and the generation of such gear
drives requires not only high-quality equipment and tools
for manufacturing of such gear drives but also the
development of the proper machine-tool settings. Such
settings are not standardized but have to be determined for
each case of design (depending on geometric parameters of
the gear drive and generating tools) to guarantee the
required quality of the gear drives.
Fig. 1 Module, spiral angle,
and number of teeth of gear
Int J Adv Manuf Technol (2010) 49:1069–1077
Table 1 Gear data
3 Manufacturing the SBG
As it was discussed in the introduction, by machining, all
types of gears can be made in all sizes, and machining is
still unsurpassed for gears having very high accuracy. Form
milling is one of the most common machining processes
used to manufacture any types of gears [14]. The cutter has
the same form as the space between adjacent teeth.
Standard cutters usually are employed in form-cutting
gears. In the USA, these cutters come in eight sizes for
each diametral pitch and will cut gears having the number
of teeth indicated in standard tables.
Gleason works used the face hobbing process that is based
on the generalized concept of bevel gear generation in which
the mating gear and pinion can be considered respectively,
generated by the complementary generating crown gears [15].
The tooth surfaces of the generating crown gears are
kinematically formed by the traces of the cutting edges of
the tool blades as shown in Fig. 2.
As it is shown in Eq. 1, velocity ratio of face hobbing
process depends on tooth number of tool and generating gear:
wt Nc
¼ ð1Þ
wc Nt
where, wt and wc denote the angular velocities of the tool and
generating gear; Nt and Nc denote the number of the blade
groups and the tooth number of the generating gear.
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Fig. 2 Generation of extended epicycloids
The radii of the rolling circles of the generating gear and
the tool are determined by Eqs. 2 and 3:
Nc
Rc ¼ s ð2Þ
Nt þ Nc
and
Nt
Rt ¼ s ð3Þ
Nt þ Nc
where s is the machine radial setting.
The generating crown gear can be considered as a special
case of a bevel gear with 90° pitch angle. Therefore, a generic
term “generating gear” is used. The concept of complementary
generating crown gear is considered when the generated
mating tooth surfaces of the pinion and the gear are conjugate.
In practice, in order to introduce mismatch of the mating tooth
surfaces, the generating gears for the pinion and the gear may
not be complementarily identical. The rotation of the
generating gear is represented by the rotation of the cradle
on a hypoid gear generator (Fig. 3).
To manufacture the SBGs with the three-axis CNC
milling machine, we first test the process by developing a
CAD/CAM system composed of geometric modeling and
graphic simulation modules. The commercial software
Solidworks is used for creating CAD model and MSC.
Visual NASTRAN 4D (CAE system of the kinematic
analysis of the mechanisms by means of their 3D models)
is used for simulating the process of gear manufacturing
and its analytical results (Fig. 4).
As far as machine tool configuration is concerned, it is
obvious that a rotational motion of the workpiece is
required for NC machining of the SBGs. Based on the
machinability analysis [16], at least four-axis controls are
required for NC machining of SBGs by one setup. Thus, a
rotary table to be interfaced with the three-axis milling
machine is required. Form cutting or form milling is used in
our tests. The tool is fed radially toward the center of the
1072
Fig. 3 Concept of bevel gear cutting
gear blank to the desired tooth depth, then across the tooth
face, while the rotary table rotates the workpiece around its
center to obtain the required tooth width. When one tooth
space has been completed, the tool is withdrawn, the gear
blank is indexed using a dividing head, and the next tooth
space is cut. Basically, this method is a simple and flexible
method of machining SBGs. The equipment and cutters
required are relatively simple, and standard three-axis CNC
milling machine is used. However, considerable care is
required on the part of tool feed which should be a small
value in each step to prevent any spoil.
We used spiral bevel gear created in GearTrax in order to
simulate operating sequence and then estimate some
machining parameters such as initial height of end mill,
location of proximity sensors, motor torque, motor speed,
and rotation frequency. For example, in SolidWorks,
Fig. 4 Simulation of cutting gear
Int J Adv Manuf Technol (2010) 49:1069–1077
Fig. 5 Motor angular velocity diagram achieved by CAE system
distance between end mill and the apex of SBG was
14.7 mm which we used to locate the spindle vertically
along the z-axis.
Also, according to the graph report of CAE system
which we used, motor angular velocity and motor torque
are 1 rpm and 48 Nm, respectively (Figs. 5 and 6).
Mastercam is a mechanical software that can be used to
generate toolpaths for machining. According to whole
depth and face width of the gear, a rectangular contour
was designed as toolpath in our cutting procedure.
Other machining parameters and tool’s specifications were
also submitted to the Tool Path menu of software. In contour
window (Fig. 7), there are two options which we use:
1. Multipasses which enable multiple stepovers of the
tool, allowing for greater control of stock removal.
2. Lead in/out which extend or shorten the toolpath before
making entry/exit moves without creating additional
geometry, which is helpful when working with control
compensation and makes it possible to program solid
contours in less time (Fig. 8).
Although the form cutting of this kind of gears is currently
done on universal milling machine, using an indexing head,
the process is slow and requires skilled labor and operator.
Figure 9 shows the arrangement that is employed when the
work is done on a universal machine in a workshop. As it is
Fig. 6 Motor torque diagram achieved by CAE system
Int J Adv Manuf Technol (2010) 49:1069–1077 1073

Fig. 7 Setting contour parameters

shown, the cutter is mounted on an arbor, and a dividing

head is used to revolve (required to cut the gear tooth) and
index the gear blank. The table is set at an angle equals to
the spiral angle (35°), and the dividing head is geared to the
longitudinal feed screw of the table so that the gear blank
will rotate as it moves longitudinally. Figure 10 shows the
simulation of traditional cutting that is mentioned above.
In the presented method, we have used an alternating
current (AC) motor interfaced with a worm gearbox. Worm
gearbox is used to reduce the output speed of AC motor and
also to set the angle between the tooth trace and the element
of the pitch cone, known as spiral angle [17].
Since synchronization between tool path planning and
rotary motion of outward shaft of worm gearbox is Fig. 8 Lead in/out parameters
required, a mechatronics system to control all the four axes
(one-axis motion for the rotary table and three-axis motion
for the cutting tool) was used simultaneously.
This mechatronics system contains five major parts:
1. Programmable logic controller, one of the electronic
equipments, which can be called “sequence controller.”
It uses internal microprocessor to execute the calcula-
tion of sequence of the work according to the status and
the value of the input signal of encoder and sensors.
2. A variable-frequency drive (VFD) is a system for
controlling the rotational speed of an AC electric motor
by controlling the frequency of the electrical power
supplied to the motor [18]. A variable-frequency drive
is a specific type of adjustable-speed drive. Variable-
frequency drives are also known as adjustable-frequency
drives, variable-speed drives, AC drives, microdrives, or
inverter drives. Since the voltage is varied along with
frequency, these are sometimes also called variable
voltage variable frequency drives [19]. We use an AC Fig. 9 A photograph of manual cutting on universal milling machine
1074
Fig. 10 Visual Nastran 4D Simulation of traditional manual cutting
on a universal milling machine with indexing head
drive as an intermediate device between PLC and AC
motor.
Some variables which were used to configure AC drive
are as follows:
1. Maximum output frequency (Fmax =60 Hz)
This parameter determines the AC drive’s maximum
output frequency. All the AC drive analog inputs (0 to +10 V,
4 to 20 mA, −10 to +10 V) are scaled to correspond to the
output frequency range.
2. Maximum voltage frequency (Fbase =60 Hz)
This value should be set according to rated frequency of the
motor as indicated on the motor nameplate. Maximum voltage
frequency determines the volts per hertz ratio. For set to
60 Hz, the drive will maintain a constant ratio of 7.66 V/Hz
(460 V/60 Hz=7.66 V/Hz). This parameter value must be
equal to or greater than the mid-point frequency.
3. Maximum output voltage (Vmax =220 V)
This parameter determines the maximum output voltage
of the AC drive. The maximum output voltage setting must
be smaller than or equal to the rated voltage of the motor as
indicated on the motor nameplate. This parameter value
must be equal to or greater than the midpoint voltage.
4. Midpoint frequency (Fmid =.5 Hz)
This parameter sets the midpoint frequency of the V/F curve.
With this setting, the V/F ratio between minimum frequency
and midpoint frequency can be determined. This parameter
must be equal to or less than maximum voltage frequency.
5. Midpoint voltage (Vmid =220 V)
This parameter sets the midpoint voltage of any V/F
curve. With this setting, the V/F ratio between minimum
Int J Adv Manuf Technol (2010) 49:1069–1077
frequency can be determined. This parameter must be equal
to or greater than minimum output voltage and equal to or
less than maximum output voltage. However, this param-
eter is ineffective when V/F curve is set to 1 to 4.
6. Minimum output frequency (Fmin =0.5 Hz)
This parameter sets the minimum output frequency of
the AC drive. This parameter must be equal to or less than
Midpoint frequency.
7. Minimum output voltage (Vmin =1.1 V)
This parameter sets the Minimum output voltage of the
AC drive. This parameter must be equal to or less than
midpoint voltage. There is a logical relationship between
different parameters in an AC drive as shown in Eq. 4:
Depends on Depends on V
Ta6 !I ! ð4Þ
F
Where T is torque, Ф is flux, I is amperage, and V and F
represent voltage and frequency. In Fig. 11, V/F curve is
shown. In a VFD, the speed of the motor is changed by
changing the frequency. Since it is desirable (not
necessarily essential) to provide the maximum torque at
any operating frequency, a VFD is designed so that the
magnetizing flux density is the same at every operating
frequency. VFDs are sometimes operated above their
normal maximum frequency without increasing the volt-
age. Up to 1.5 to 2 times the normal frequency, the
available torque reduction follows a curve that is often
sufficient to provide constant power operation.
3. Rotary encoder, also called a shaft encoder, is an
electromechanical device used to convert the angular
position of a shaft or axle to an analog or digital code,
making it an angle transducer. It can determine the
position of outward shaft or measure the revolution of
workpiece mounted on outward shaft.
Fig. 11 V/F curve
Int J Adv Manuf Technol (2010) 49:1069–1077
Fig. 12 Encoder-operating principle
In general, as it is shown in Fig. 12, the light emitted by
an LED passes through the slit of a rotating disk and a
stationary mask to produce an electronic output from a
photodiode array according to the pattern on the disk. The
most common encoders provide a digital pulse for each
resolvable position to be counted and referenced to a home
position. These digital pulses are then fed into a high-speed
counter module located in a drive or controller interface.
4. Proximity sensors, which produce an output signal if a
metal object (form cutter in our experiment) enters the
electromagnetic field of its oscillator. Two proximity
sensors are placed on the system where define the start
and end of the tool path.
In this procedure, two indicator stands have been used in
order to control the location of proximity sensors more
freely (Fig. 13).
5. A photoelectric sensor, a device used to detect the
presence of an object by using a light transmitter which
consists of a receiver located within the line-of-sight of
the transmitter. Table 2 shows basic specifications of
Fig. 13 Proximity sensor and indicator stand in SolidWorks
1075
Table 2 Photoelectric sensor specifications
Model Cable Detecting Min. detecting
length (L) target (mm) target
FT-320-05 2 m 150 D0.5
the photoelectric sensor that we used in this research.
The power supply has two states of light on mode and
dark on mode. In the first state, the control output turns
on by receiving light and turns off by interrupting light.
In the second state, the control output turns off by
receiving light and turns on by interrupting light. In this
mode, an object is detected when the light beam is
blocked from getting to the receiver from the transmit-
ter. These sensors should be installed on a ring
concentric with output shaft; this ring works as a
friction bearing and rotate in an outer ring. Output shaft
and above ring are connected using a hub system.
Light beam passes through a track on shaft from the
transmitter to receiver on opposite sides. It evaluates
absence or presence based on transmittance or blockage of
the beam, respectively.
We used ladder diagram, common program language to
operate the PLC in the mechatronics system that it is shown
in Fig. 14.
The operation of the PLC based on the ladder diagram is
as follows:
Step 1 Read the external input signal, such as the status
of sensors or rotary encoder.
Step 2 Calculate output signal, according to the value of
the input signal in step 1 and send it to AC drive
(Inverter) to run the AC motor in forward/reverse
direction or turn the motor for a special angle
(circular pitch) using a rotary encoder. Having set
up the CNC milling machine, the procedure of the
whole system is accomplished in five stages:
Stage 1 Form cutter reaches the first proximity sensor
(orange one as it is shown in Fig. 16). As soon as
sensor 1 detects the form cutter, it sends a +5-V
signal to the PLC. As it is mentioned before,
PLC sends out an output signal to the AC drive
to run the motor in forward direction.
Stage 2 Form cutter machines the rotating workpiece with
respect to the toolpath has been generated in
Mastercam.
Stage 3 Cutting tool reaches the second proximity sensor
(green one). Detecting form cutter by sensor 2, it
sends the second signal to the PLC and PLC
sends a stop command to the inverter.
Stage 4 Milling tool withdraws the stopped workpiece and
returns to its first place. Simultaneously, AC drive
1076 Int J Adv Manuf Technol (2010) 49:1069–1077

Fig. 16 A photograph of machined SBG

Fig. 14 A photograph of electrical panel including PLC and inverter

runs the motor in backward direction until the

shaft reaches the first position which the receiver
of photoelectric sensor sees the transmitted
radiation passes through the longitudinal crack
on the output shaft.
Stage 5 Stages 1 through 4 continue until the first tooth
space is cut. PLC counts a number for each of the
above four stages until it reaches the predefined
number of machining sequences. Then, it sends out
a signal to the AC drive to index the gear blank

Fig. 15 A photograph of the experimental cutting Fig. 17 An overall picture of cutting spiral bevel gear
Int J Adv Manuf Technol (2010) 49:1069–1077
equal to diametral pitch, and all the above stages will
be repeated again. The diametral pitch is measured
by a 1,024-pulse/revolution rotary encoder.
The traditional procedure (Fig. 9) is quite slow, and
considerable care is required by the operator. Likewise, the
procedure utilized is essentially the same as on a universal
milling machine. In contrast, after setup, the various
operations are completed automatically. The machining
configuration and a photocopy of the experimental cutting
are shown in Figs. 15 and 16.
In an advantageous embodiment of the method accord-
ing to the present invention, machining time is one of the
most factors which have been greatly noted. For example, it
took only 2 min to cut one tooth space completely. While,
in traditional method, it took more than half an hour to cut
same tooth space.
In a further advantageous embodiment of the present
invention with respect to manual cutting, the instant for the
angular compensation of the cutter head is set shortly
before the end of the plunge process.
4 Machining strategy
The workpiece is wood, and the blank material is prema-
chined as a conic (face angle of the gear) form by turning
operation. Standard cutter No. 5 used in our experiment is
mounted on the machine spindle, and the gear blank is
mounted on outward shaft of worm gearbox. The tool is fed
subsequently (around 30 machining sequences to prevent
spoiling work) toward the center of the gear blank to the
desired tooth depth. When one tooth space has been
completed, the tool is withdrawn; the gear blank is indexed
using the AC motor based on explained procedure and then
is followed by cutting the next tooth space.
Having looked at all the mentioned stages above, the
following diagram can be considered as an overall picture
of this invention (Fig. 17).
5 Conclusions
In this paper, we attempted to manufacture the spiral bevel
gear using a three-axis CNC milling machine based on
form milling method. For such a purpose, we investigated a
CAD/CAM model of cutting procedure and also tool path
computing algorithm. All previous works have been
concerned with the design aspect using complicated
mathematical procedure, and experimental manufacturing
methods have not been explicitly focused. Basically, form
cutting uses a simple and flexible method of machining of
gears. The equipment and cutters required are relatively
1077
simple and inexpensive, and standard CNC milling ma-
chine is used. So, it does not need skilled operator to set up
the system. Compared to the conventional gear cutting
method in which dedicated machine tools is required, the
presented method can easily be modified to produce any
type and size of SBGs or any other types of gears. In
comparison to manual cutting machine, it is a complete
automatic method in which all machining parameters are
derived from the computer model. It is also a multi-
deception system (use of mechatronic and CNC systems)
which is a dynamic and constant evolving technology.
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