While the automotive and truck industry conducted substantial research in the application of face gear
systemsin theirdrivetrains, theresultsdid notfavorfacegearsversusbevel and hypoid gears. In manycases,
thefacegearsystem wasfound thelesseconomical solution. Although, atfirstitseemstheopposite, sincethe
driving pinion in afacegearunitcan beproduced morecosteffectivethen abevel pinion, the manufacturing of
thefacegearitselfwasexpensive. Machinetoolsrequireaspecial design and arenotreadilyavailableand the
cutting tools have to be designed specifically for the particular face gear design.
Theobstacleswhich prevented manufacturersin thepasttoapplyfacegearswereremoved entirely, when the
Bevel Gear Technology Group at The Gleason Works invented a new way of forming the profile of face gear
teeth, using standard bevel gear cutting and grinding machines as well as standard cutter heads. The idea is
based on the tools used in straight bevel gear cutting and grinding according to the CONIFLEX method,
however, using a generating gear which is not flat like it is for straight bevel gears but cylindrical, resembling
the mating cylindrical pinion for the particular face gear design.