Optimization of cutter blade profile for face-hobbed spiral bevel gears

To eliminate the tooth edge contact and improve the distribution of the tooth contact stress for face-hobbed spiral bevel gears in the case of heavy load and misalignment considered, optimizing the cutter blade profile is one of the most effective solutions. Generally, a segment of circle arc is used to substitute the straight line to get a desired theoretical tooth contact pattern, however, which is not sufficient for a heavy-loaded gear pair. A multi-segment cutter blade profile with Toprem, Flankrem, and cutter tip is introduced to obtain the ideal load and contact stress distribution. First, the structure of cutter head is described geometrically, the mathematical model of new cutter blade profile is built, and the equation for each section is given in detail. Then, the calculations of all design parameters are represented step by step. Finally, a contrast experiment between the original cutter and new optimal cutter, including tooth contact analysis, finite element analysis, and practical rolling check, is carried out for Oerlikon hypoid gears to verify effectiveness.

[1]  Vilmos Simon,et al.  Optimal Machine-Tool Settings for the Manufacture of Face-Hobbed Spiral Bevel Gears , 2014 .

[2]  Vilmos Simon.  Influence of Tooth Modifications on Load Distribution in Face-Hobbed Spiral Bevel Gears , 2011 .

[3]  Qi Fan,et al.  Enhanced Algorithms of Contact Simulation for Hypoid Gear Drives Produced by Face-Milling and Face-Hobbing Processes , 2007 .

[4]  Vilmos Simon,et al.  Advanced manufacture of spiral bevel gears on CNC hypoid generating machine , 2010 .

[5]  Qi Fan.  Tooth Surface Error Correction for Face-Hobbed Hypoid Gears , 2010 .

[6]  V. Simon.  Generation and Tooth Contact Analysis of Face-Hobbed Spiral Bevel Gears , 2011 .

[7]  Vilmos Simon,et al.  Generation of Hypoid Gears on CNC Hypoid Generator , 2011 .

[8]  Vilmos Simon,et al.  Design of face-hobbed spiral bevel gears with reduced maximum tooth contact pressure and transmission errors , 2013 .

[9]  Kazumasa Kawasaki,et al.  Analytical and Experimental Tooth Contact Pattern of Large-Sized Spiral Bevel Gears in Cyclo-palloid System , 2010 .

[10]  Vilmos Simon,et al.  Head-cutter for optimal tooth modifications in spiral bevel gears , 2009 .

[11]  Kazumasa Kawasaki,et al.  Effect of Cutting Edge Profile on Meshing and Contact of Spiral Bevel Gears in Cyclo-Palloid System , 2005 .

[12]  Yi-Pei Shih,et al.  Flank Modification Methodology for Face-Hobbing Hypoid Gears Based on Ease-Off Topography , 2007 .

[13]  Vilmos Simon,et al.  Manufacture of Optimized Face-Hobbed Spiral Bevel Gears on Computer Numerical Control Hypoid Generator , 2014 .

[14]  Vilmos Simon.  Minimization of the Influence of Misalignments on EHD Lubrication in Face-Hobbed Spiral Bevel Gears , 2013 .

[15]  Yi-Pei Shih,et al.  Mathematical Model for a Universal Face Hobbing Hypoid Gear Generator , 2007 .

[16]  V. Simon.  Optimal Tooth Modifications in Face-Hobbed Spiral Bevel Gears to Reduce the Influence of Misalignments on Elastohydrodynamic Lubrication , 2014 .

[17]  Zong De Fang,et al.  Mathematical Model of Klingelnberg Cyclo-Palloid Hypoid Gear , 2013 .

[18]  V. Simon.  Advanced Design and Manufacture of Face-Hobbed Spiral Bevel Gears , 2009 .

[19]  Faydor L. Litvin,et al.  Generation and geometry of hypoid gear-member with face-hobbed teeth of uniform depth , 1991 .