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

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Xingyu Yang ◽  
Chaosheng Song ◽  
Caichao Zhu ◽  
Siyuan Liu ◽  
Chengcheng Liang
Keyword(s):  
Manufacturing Process ◽  
Computational Study ◽  
Cone Angle ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Contact Pattern ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Shaft Angle

Abstract 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.

Coupled Tooth Contact Analysis of Intersected Beveloid Gears for Marine Transmissions

2013 ◽  
Author(s):  
Caichao Zhu ◽  
Haixia Wang ◽  
Mingyong Liu ◽  
Xuesong Du ◽  
Chaosheng Song
Keyword(s):  
Gear Tooth ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Contact Patterns ◽  
Beveloid Gears ◽  
Shaft Angle ◽  
Loaded Tooth Contact Analysis ◽  
Mesh Condition

Beveloid gears are widely applied in fields like ships, automobiles and industrial precision transmissions. In this paper, the formulas of the beveloid gear tooth surface used in marine transmissions were derived and a mesh model for the intersected beveloid gear pair was setup. Then loaded tooth contact analysis was performed using the finite element method considering the coupling of the assembly errors and the elastic deformation of tooth surface. Through the analysis, the influences of assembly errors on contact patterns, mesh force and tooth surface deformations were investigated. In a further step, the tooth profile modifications were performed to alleviate the edge contact and a subsequent major improvement of the mesh condition was obtained. Finally, loaded tooth contact experiments for marine gearboxes with small shaft angle were conducted. The tested results showed good correlation with the computed results. This work may provide some value for the practical design aiming at improved contact characteristics of the beveloid gears with intersected axes.

Mathematical Model of Klingelnberg Cyclo-Palloid Hypoid Gear

2013 ◽  
Vol 341-342 ◽  
pp. 572-576 ◽  
Author(s):  
Jin Fu Du ◽  
Zong De Fang ◽  
Min Xu ◽  
Xing Long Zhao ◽  
Yu Min Feng
Keyword(s):  
Mathematical Model ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Hypoid Gears ◽  
Tooth Surfaces ◽  
Normal Vectors

The geometry of the tooth surface is important for tooth contact analysis, load tooth contact analysis and the ease-off of gear pairs. This paper presents a mathematical model for the determination of the tooth geometry of Klingelnberg face-hobbed hypoid gears. The formulation for the generation of gear and pinion tooth surfaces and the equations for the tooth surface coordinates are provided in the paper. The surface coordinates and normal vectors are calculated and tooth surfaces and 3D tooth geometries of gear and pinion are obtained. This method may also applied to other face-hobbing gears.

An Ease-Off Based Method for Loaded Tooth Contact Analysis of Hypoid Gears Having Local and Global Surface Deviations

2010 ◽  
Vol 132 (7) ◽  
Author(s):  
M. Kolivand ◽  
A. Kahraman
Keyword(s):  
Gear Tooth ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Hypoid Gears ◽  
Surface Deviations ◽  
Tooth Surfaces ◽  
Loaded Tooth Contact Analysis

Actual hypoid gear tooth surfaces do deviate from the theoretical ones either globally due to manufacturing errors or locally due to reasons such as tooth surface wear. A practical methodology based on ease-off topography is proposed here for loaded tooth contact analysis of hypoid gears having both local and global deviations. This methodology defines the theoretical pinion and gear tooth surfaces from the machine settings and cutter parameters, and constructs the surfaces of the theoretical ease-off and roll angle to compute for the unloaded contact analysis. This theoretical ease-off topography is modified based on tooth surface deviations and is used to perform a loaded tooth contact analysis according to a semi-analytical method proposed earlier. At the end, two examples, a face-milled hypoid gear set having local deviations and a face-hobbed one having global deviations, are analyzed to demonstrate the effectiveness of the proposed methodology in quantifying the effect of such deviations on the load distribution and the loaded motion transmission error.

An Improved Algorithm for Tooth Contact Analysis for Hypoid Gear Based on Axial Section Programming

2010 ◽  
Vol 44-47 ◽  
pp. 1392-1396
Author(s):  
Wei Wei ◽  
Lian Hong Zhang
Keyword(s):  
Contact Analysis ◽  
Tooth Surface ◽  
Particle Swarm Algorithm ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Axial Section ◽  
Tooth Contact ◽  
Boundary Points ◽  
Variable Substitution ◽  
Improved Algorithm

An improved algorithm of tooth contact analysis (TCA) is proposed to overcome the deficiency of the current TCA algorithm for hypoid gear. The key improvement of the proposed algorithm is to introduce proportional coefficients of tooth length and tooth height in TCA. The solution domain of the nonlinear equations in TCA is limited in the range of tooth surface by variable substitution. By analyzing the positions which boundary points possibly appear on axial section, the values of proportional coefficients corresponding to the positions are obtained. Boundary points of the contact trace are computed with particle swarm algorithm and conjugate gradient method, and distributed points on the contact trace are solved according to information of boundary points. With the improved algorithm the boundary points of the contact trace can be figured out accurately and there is no need to set initial values for tooth contact analysis.

Tooth Contact Analysis and Manufacture on Multitasking Machine of Large-Sized Straight Bevel Gears With Equi-Depth Teeth

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
Isamu Tsuji ◽  
Kazumasa Kawasaki ◽  
Hiroshi Gunbara ◽  
Haruo Houjoh ◽  
Shigeki Matsumura
Keyword(s):  
Contact Analysis ◽  
Tooth Surface ◽  
Contact Pattern ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Form Errors ◽  
Bevel Gears ◽  
Computer Aided ◽  
Tooth Surfaces ◽  
Tooth Flank

Straight bevel gears are widely used in the plant of large-sized power generation when the gears have large size. The purpose of this study is to manufacture the large-sized straight bevel gears with equi-depth teeth on a multitasking machine. The manufacturing method has the advantages of arbitrary modification of the tooth surface and machining of the part without the tooth surface. For this study, first, the mathematical model of straight bevel gears by complementary crown gears considering manufacture on multitasking machine is proposed, and the tooth contact pattern and transmission errors of these straight bevel gears with modified tooth surfaces are analyzed in order to clarify the meshing and contact of these gears. Next, the numerical coordinates on the tooth surfaces of the bevel gears are calculated and the tooth profiles are modeled using a 3D-Computer-Aided Design (CAD) system. Five-axis control machines were utilized. The gear-work was machined by a swarf cutting using a coated carbide end mill. After rough cutting, the gear-work was heat-treated, and it was finished based on a Computer-Aided Manufacturing (CAM) process through the calculated numerical coordinates. The pinion was also machined similarly. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. As a result, the obtained tooth flank form errors were small. In addition, the tooth contact pattern of the manufactured large-sized straight bevel gears was compared with those of tooth contact analysis. The data showed good agreement.

Tooth Contact Analysis and Manufacture on Multi-Tasking Machine of Large-Sized Straight Bevel Gears

2011 ◽  
Author(s):  
Kazumasa Kawasaki ◽  
Isamu Tsuji ◽  
Hiroshi Gunbara
Keyword(s):  
Contact Analysis ◽  
Tooth Surface ◽  
Contact Pattern ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Form Errors ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Tooth Flank ◽  
Coated Carbide

Straight bevel gears are widely used in the plant of large-sized power generation when the gears have large size. The purpose of this study is to manufacture the large-sized straight bevel gears with equi-depth on multi-tasking machine. The manufacturing method has the advantages of arbitrary modification of the tooth surface and machining of the part without the tooth surface. For this study, first the mathematical model of straight bevel gears by complementary crown gears considering manufacture on multi-tasking machine is proposed, and the tooth contact pattern and transmission errors of these straight bevel gears with modified tooth surfaces are analyzed in order to clarify the meshing and contact of these gears. Next, the numerical coordinates on the tooth surfaces of the bevel gears are calculated and the tooth profiles are modeled using a 3D-CAD system. 5-axis control machines were utilized. The gear-work was machining by a swarf cutting using a coated carbide end mill. After rough cutting, the gear-work was heat-treated, and it was finished based on a CAM process through the calculated numerical coordinates. The pinion was also machined similarly. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. As a result, the obtained tooth flank form errors were small. In addition, the tooth contact pattern of the manufactured large-sized straight bevel gears was compared with those of tooth contact analysis. As a result, there was good agreement.

Simulation and Experimental Measurement of the Transmission Error of Real Hypoid Gears Under Load

2000 ◽  
Vol 122 (1) ◽  
pp. 109-122 ◽  
Author(s):  
Claude Gosselin ◽  
Thierry Guertin ◽  
Didier Remond ◽  
Yves Jean
Keyword(s):  
Measurement Data ◽  
Simulation Models ◽  
Transmission Error ◽  
Contact Analysis ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Hypoid Gears ◽  
Loaded Tooth Contact Analysis ◽  
Analysis Models

The Transmission Error and Bearing Pattern of a gear set are fundamental aspects of its meshing behavior. To assess the validity of gear simulation models, the Transmission Error and Bearing Pattern of a Formate Hypoid gear set are measured under a variety of operating positions and applied loads. Measurement data are compared to simulation results of Tooth Contact Analysis and Loaded Tooth Contact Analysis models, and show excellent agreement for the considered test gear set. [S1050-0472(00)00901-6]

2213 Tooth Contact Analysis of Hypoid Gear of Gleason Method

2006 ◽  
Vol 2006.6 (0) ◽  
pp. 229-230
Author(s):  
Minoru MAKI ◽  
Masaki WATANABE ◽  
Akira YAMAMOTO ◽  
Takao SHIGEMI
Keyword(s):  
Contact Analysis ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact

Loaded Tooth Contact Pattern Analysis for Strain Wave Gear With Non-Elliptical Wave Generator

2019 ◽  
Author(s):  
Zhiyuan Yu
Keyword(s):  
Finite Element ◽  
Pattern Analysis ◽  
Element Model ◽  
Tooth Surface ◽  
New Wave ◽  
Contact Pattern ◽  
Strain Wave ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Wave Generator

Abstract This paper presents a new non-elliptical wave generator for strain wave gear to improve its contact pattern quality. The new wave generator has a polynomial profile at one cross section, then crowned along the lead direction. The lead crowning uses a parabolic function with crowning amount controlled by parabolic coefficient. Loaded tooth contact pattern analysis based on finite element method is used to evaluate the new design. The result shows that the new design will avoid the edge contact between wave generator and flexspline, which reduces contact pressure and improve the wearing life of the gear. It also improves the contact pattern quality of the tooth surface. Comparing with elliptical wave generator, the new wave generator with polynomial profile and lead parabolic crowned surface offers more design freedom to improve strain wave gear’s performance. The parametric equation of the new wave generator is defined intuitively, and it can be easily adapted for any type of strain wave gear. Furthermore, the finite element model for the strain wave gear is a new development and application for Loaded Tooth Contact Analysis (LTCA).

Real Tooth Contact Analysis of Hypoid Gear Without Using Mathematical Reference Tooth Surfaces

2005 ◽  
Author(s):  
Keiichiro Tobisawa ◽  
Masaki Kano ◽  
Kohei Saiki ◽  
Tsuyoshi Hanakawa ◽  
Takeshi Yokoyama
Keyword(s):  
Contact Analysis ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Tooth Surfaces
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