Patent ID: 8491236

Claim:
A method for machining a tooth surface of a toothed member, the toothed member having a cylindrical portion with teeth extending from the cylindrical portion, and the tooth surface being formed on a periphery of one of the teeth of the toothed member and extending in a direction of a center axis of the toothed member, the method comprising: providing a machine tool configured to rotate an end mill about a longitudinal axis thereof, the machine tool being configured to move the end mill along two linear axes of a three-axis Cartesian axis system, the machine tool also including a rotation mechanism and a tailstock between which the toothed member is clamped so as to be rotated by the rotation mechanism and linearly moved along the third Cartesian axis, the machine tool not being configured to provide any further relative movements between the end mill and the toothed member beyond the rotation of the end mill, the rotation of the toothed member, and the linear movements along the three Cartesian axes, approximating a curve line with a series of straight lines, the curve line being a design shape of the tooth surface in a cross-sectional plane transverse to and intersecting with the center axis of the toothed member, the approximating being performed so that a maximum distance among distances between respective ones of the straight lines included in the series of straight lines and the curve line is less than a machining tolerance of the tooth surface, first cutting of one of the straight lines of the tooth surface by only using a peripheral cutting edge of an end mill while keeping the rotation axis of the end mill at an orientation parallel to said one straight line among the straight lines and moving the toothed member parallel to the center axis of the toothed member, rotating the toothed member around the center axis of the toothed member via the rotation mechanism so that the orientation of the rotation axis of the end mill becomes parallel to another straight line among the straight lines included in the series of straight lines, and second cutting of said another straight line of the tooth surface by only using the peripheral cutting edge of the end mill while keeping the rotation axis of the end mill at the same orientation as that in the first cutting and parallel to the another straight line among the straight lines included in the series of straight lines and moving the toothed member parallel to the center axis of the toothed member.