Simulation of spiral bevel gear manufacturing by face hobbing and prediction of the cutting forces using a novel CAD-based modelSimulation of spiral bevel gear manufacturing by face hobbing and prediction of the cutting forces using a novel CAD-based model Peer-Reviewed Journal Publication Δημοσίευση σε Περιοδικό με Κριτές 2024-04-112022enThe BevelSim3D algorithm has been developed for the simulation of spiral bevel gear manufacturing. The model aims to achieve the 3D kinematic simulation of face milling and face hobbing, the generation of the undeformed solid chip geometry, and the solid tooth flank geometry. In addition, another novel calculation algorithm, called BevelForce3D, has been developed to calculate the cutting forces using the aforementioned produced undeformed chip geometries. The simulation results are validated with the geometric comparison of the simulated tooth flank geometry with the theoretical gear geometry, via the novel validation algorithm BevelCurve3D. The simulation methodology for face milling has been already described by the authors in previous work. The current study extends the functionality of the simulation model with the introduction of the face hobbing simulation and the calculation of cutting forces. Results including solid tooth flank geometry, solid chip geometry, and calculated cutting forces are presented and discussed in the paper. Investigation of the effect of crucial cutting parameters, such as generating feedrate, on the quality of the produced surface, is included in the results. Finally, the effect of three parameters, i.e., finishing stock allowance, plunge feedrate, and generating feedrate, on the undeformed chip geometry and thus the developed cutting forces, is investigated.This study is funded as part of NSRF 2014–2020 by the State Scholarships Foundation of Greece, through the doctoral scholarship awarded to Chara Efstathiou.http://creativecommons.org/licenses/by/4.0/International Journal of Advanced Manufacturing Technology1229–103789–3813 Efstathiou Charikleia Ευσταθιου Χαρικλεια Tapoglou Nikolaos Springer Spiral bevel gears Face hobbing 3D kinematic simulation CAD Cutting forces