Method and tool for manufacturing spiral tooth face couplings

A method of manufacturing spiral tooth face couplings having a plurality of teeth with each of said teeth having concave and convex tooth flanks, said method comprising:

• providing a face hobbing cutter rotatable about a cutter axis and having a plurality of cutting blade slots arranged spaced about a face of the cutter with at least a first cutting blade and a second cutting blade positioned in each of said slots, wherein said first and second cutting blades in each of said slots being spaced from one another by a spacing angle,
• rotating said face hobbing cutter and rotating a face coupling workpiece,
• engaging said face hobbing cutter with said face coupling workpiece in a continuous indexing manner at a first machining position, wherein one of said first cutting blade and said second cutting blade produces one of a finished concave or a finished convex tooth flank surface on each of said teeth of said face coupling workpiece,
• repositioning said face hobbing cutter and said face coupling workpiece at a second machining position based on said spacing angle, and
• engaging said face hobbing cutter with said face coupling workpiece in a continuous indexing manner at said second machining position, wherein the other of said first cutting blade and said second cutting blade produces the other of a finished concave or a finished convex tooth flank surface on each of said teeth of said face coupling workpiece.