This paper presents a new systematic method for identifying the values of the machine-tool settings required to obtain flank form modifications in hypoid gears. The problem is given a nonlinear least-squares formulation, and it is solved by the Levenberg–Marquardt method with a trust-region strategy. To test the method, the same ease-off topography was obtained by means of very different sets of machine-tool settings, including a set of only kinematic parameters and a highly redundant set of 17 parameters. In all cases, the goal was achieved in a few iterations, with residual errors well below machining tolerances and, even more importantly, with realistic values of all parameters. Therefore, significant improvements in practical gear design can be achieved by employing the overall proposed procedure.
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