Abstract: In order to improve the processing efficiency of cylindrical gears and the bearing capacity of gear pairs,a new type of rapid prototyping method for plane helical cylindrical gears is proposed,that is,the gears are milled quickly by using a large rotating cutter head,multiple tool bars and blades are arranged according to the plane helical line to continuously cut the tooth groove of the gear,the pitch of the plane helix is equal to the pitch of the gear to be processed,the cutter head rotates one circle and the gear to be processed rotates one tooth,realizing continuous and rapid cutting of the gear processing,the feasibility of this method is verified through VERICUT processing simulation; a special processing machine tool is developed to implement the processing of new gears; the main parameters of the processed plane helical cylindrical gear are clarified,the tooth line radius of the concave tooth surface are slightly larger than the radius of the tooth line of the convex tooth surface,the teeth are slightly drum-shaped,which can reduce the meshing load of the gear pair. Through the three-dimensional meshing analysis of the plane helical cylindrical gear pair,it is concluded that the contact interval of the plane helical cylindrical gear pair is mainly distributed in the middle part of the contact tooth surface,and the force on both ends of the gear teeth gradually decreases,effectively reducing the bending stress at the tooth root at both ends of the gear teeth and improving the bearing capacity of the gear pair.

Key words: large cutter head, rapid prototyping, plane helical cylindrical gear, meshing partial load