Bevel Gear Chamfering via Brushing to Contain Shot Peening Plus Tips

The patent applies preliminary action by forming chamfers on the gear teeth before the shot peening process. This pre-prepared chamfer geometry provides a designated zone where plus tips can form during shot peening without affecting the critical meshing surfaces, thereby preventing tooth profile distortion and misalignment while still allowing the shot peening to strengthen the gear teeth.

The patent replaces traditional mechanical cutting methods (CNC gear cutting, hobbing) with a combination of face milling followed by shot peening. This substitution transforms the gear tooth formation process from direct mechanical cutting to a two-stage process where face milling creates the basic tooth geometry and shot peening subsequently strengthens the teeth while forming controlled plus tips within chamfer zones, thereby improving meshing reliability and reducing wear.

The patent applies the taking out principle by extracting the harmful effect of plus tip formation from the critical meshing engagement zone. By designing chamfers that redirect plus tip formation to specific non-critical areas, the patent separates the beneficial surface strengthening effect from the harmful meshing disruption, allowing shot peening to strengthen the gear surface while containing NVH-generating plus tips within the chamfer zones.