Computational Study on Machine Settings for Face-Milled Hypoid Gears With Low Shaft Angles

Hypoid gear with small cone angle and large pitch cone distance can be directed at the transmission with low shaft angle (LSA). The manufacturing process has more freedoms of motion to control the tooth surface and ensure higher mesh performance. However, it is difficult to adjust the machine settings due to the extreme geometry. This paper focused on the manufacturing process and machine settings calculation of hypoid gear with low shaft angle (LSA hypoid gear). Based on the generating process, nongenerated gear, and generated pinion manufactured by circular cutter blade, the mathematic model of tooth surface of LSA hypoid gear was developed, and the expressions of principal directions and curvatures of LSA hypoid gear were derived. The relationship of curvatures between pinion and gear was also proposed. Then based on the basic relationships of two mating surfaces, an approach to determinate machine settings for LSA hypoid gear was proposed. Finally, the tooth contact analysis (TCA) and loaded tooth contact analysis (LTCA) were directed at the validation of machine settings’ derivation. TCA contact pattern results highly coincide with the preset values. And the LTCA contact pattern also highly coincides with TCA results, it can be considered that the determination approach of machine settings is valid. The TCA transmission error result also shows that the ratio of contact is quite large, which is a little bigger than 2. Thus, the load bearing ability and stability of LSA hypoid gear may be superior.