An Investigation on the Design of Formate and Generate Face Milled Hypoid Gears

2020 ◽  
Author(s):  
Tufan Gürkan Yılmaz ◽  
Onur Can Kalay ◽  
Fatih Karpat ◽  
Mert Doğanlı ◽  
Elif Altıntaş
Keyword(s):  
Power Transmission ◽  
Face Milling ◽  
Tool Geometry ◽  
Hypoid Gear ◽  
Mathematical Equation ◽  
Spiral Bevel Gears ◽  
Hypoid Gears ◽  
Bevel Gears ◽  
Milling Method ◽  
Spiral Bevel

Abstract Hypoid gears are transmission elements that transfer power and moment between shafts whose axes do not intersect. They are similar in structure to spiral bevel gears. However, there are many advantages compared to spiral bevel gears in terms of load carrying capacity and rigidity. Hypoid gear pairs are mostly used as powertrain on the rear axles of cars and trucks. Hypoid gears are manufactured by two essential methods called face-milling and face-hobbing, and there are mainly two relative kinematic movements (Formate® and Generate). In this study, the gears produced with the Face-milling method are discussed. Face milled hypoid gears can be manufactured with both Formate® and Generate, while pinions can only be manufactured with the Generate method. The most crucial factor that determines the performance of hypoid gears is the geometry of hypoid gears. The gear and pinion geometry is directly dependent on the tool geometry, machine parameters, and relative motion between the cradle and the workpiece. The gear geometry determines the contact shape and pressure during power transmission. In this study, the mathematical equation of the cutting tool is set. After that, using differential geometry, coordinate transformation, and the gearing theory, the mathematical equation of hypoid gear is obtained.

Generation of Noncircular Spiral Bevel Gears by Face-Milling Method

2016 ◽  
Vol 138 (8) ◽  
Author(s):  
Fangyan Zheng ◽  
Lin Hua ◽  
Dingfang Chen ◽  
Xinghui Han
Keyword(s):  
Face Milling ◽  
Cnc Machining ◽  
Tooth Surface ◽  
Free Form ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Milling Method ◽  
Spiral Bevel ◽  
Crown Gear

Noncircular bevel gears are applied in variable-speed transmissions with intersecting axes. Since dedicated machines for manufacturing noncircular bevel gears are not available, noncircular bevel gears are normally manufactured using universal computer numerically controlled (CNC) machining centers, resulting in poor productivity. This paper describes a face-milling method for generation of noncircular spiral bevel gears, which is analogous to the generation of spiral bevel and hypoid gears using CNC hypoid gear generators, such as Gleason free-form hypoid generators. As a result, the productivity is significantly improved. Based on the theory of gearing, this paper first describes the basic concept of generation of conjugate noncircular spiral bevel gears. Generation of the tooth surfaces using crown-gear generation concept is analytically discussed with association to the face-milling process of generation of the proposed noncircular spiral bevel gears. The tooth surface geometries are represented by the position vectors and normals. The kinematical model of free-form machines is developed. The machine motion parameters are determined based on the theoretically defined tooth surfaces using the crown-gear generation concept. The developed method is verified by manufacturing a real pair of noncircular spiral bevel gears with satisfactory contact patterns which agree well with those modeled using a commercial cae software program.

Spiral Bevel Gears CNC Milled by Disc Cutter with Concave End

2013 ◽  
Vol 415 ◽  
pp. 636-641
Author(s):  
Xiao Zhong Deng ◽  
Geng Geng Li ◽  
Bing Yang Wei
Keyword(s):  
Face Milling ◽  
Strip Width ◽  
Disc Cutter ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Cutter Orientation ◽  
End Mills ◽  
Spiral Bevel ◽  
Yaw Angle

In order to solve the small cutting strip width and poor surface quality problems when spiral bevel gears are CNC machined by ball-end mills£¬a machining method of face milling spiral bevel gears by using a disc cutter with a concave end is presented. Based on the researches of spiral bevel gears geometry structure, through a bigger diameter disc cutter with a concave end selected, the setting order of cutter orientation angles changed, and the functions of cutter tilt and yaw angle separated, tooth surfaces machined with big cutting strip width and no bottom land gouge can be expected. Finally, taking a spiral bevel gear pair as an example, through machining and measurement experiments, the method feasibility and correctness are verified

The fundamental roughness model for face-milling spiral bevel gears considering run-outs

2019 ◽  
Vol 156 ◽  
pp. 272-282 ◽  
Author(s):  
Fangyan Zheng ◽  
Mingde Zhang ◽  
Weiqing Zhang ◽  
Rulong Tan ◽  
Xiaodong Guo
Keyword(s):  
Face Milling ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Roughness Model ◽  
Spiral Bevel

Mathematical Model for a Universal Face Hobbing Hypoid Gear Generator

2006 ◽  
Vol 129 (1) ◽  
pp. 38-47 ◽  
Author(s):  
Yi-Pei Shih ◽  
Zhang-Hua Fong ◽  
Grandle C. Y. Lin
Keyword(s):  
Mathematical Model ◽  
Object Oriented ◽  
Face Milling ◽  
Object Oriented Programming ◽  
Hypoid Gear ◽  
Hypoid Gears ◽  
Proposed Model ◽  
Spiral Bevel ◽  
Cutter Head ◽  
Cutting System

Based on the theory of gearing and differential geometry, a universal hypoid generator mathematical model for face hobbing spiral bevel and hypoid gears has been developed. This model can be used to simulate existing face hobbing processes, such as Oerlikon’s Spiroflex© and Spirac© methods, Klingelnberg’s Cyclo-Palloid© cutting system, and Gleason’s face hobbing nongenerated and generated cutting systems. The proposed model is divided into three modules: the cutter head, the imaginary generating gear, and the relative motion between the imaginary generating gear and the work gear. With such a modular arrangement, the model is suitable for development of object-oriented programming (OOP) code. In addition, it can be easily simplified to simulate face milling cutting and includes most existing flank modification features. A numerical example for simulation of the Klingelnberg Cyclo-Palloid© hypoid is presented to validate the proposed model, which can be used as a basis for developing a universal cutting simulation OOP engine for both face milling and face hobbing spiral bevel and hypoid gears.

Enhanced Algorithms of Contact Simulation for Hypoid Gear Drives Produced by Face-Milling and Face-Hobbing Processes

2006 ◽  
Vol 129 (1) ◽  
pp. 31-37 ◽  
Author(s):  
Qi Fan
Keyword(s):  
Face Milling ◽  
Numerical Control ◽  
Surface Generation ◽  
Tooth Surface ◽  
Free Form ◽  
Generic Model ◽  
Hypoid Gear ◽  
Hypoid Gears ◽  
Contact Patterns ◽  
Spiral Bevel

Modeling of tooth surface generation and simulation of contact is an important part of computerized design and manufacturing of spiral bevel and hypoid gears. This paper presents new developments in this subject. Specifically, the paper covers: (i) development of a generic model of tooth surface generation for spiral bevel and hypoid gears produced by face-milling and face-hobbing processes conducted on free-form computer numerical control (CNC) hypoid gear generators which are incorporated with the Universal Motions Concept (UMC); (ii) a modified algorithm of tooth contact simulation with reduced number of equations of the nonlinear iterations and stabilized iteration convergence; and (iii) an algorithm of numerical determination of contact lines that form the contact patterns. The enhanced approach of contact simulation can be generally applied to other forms of gearings. Two examples, a face-hobbing design and a face-milling design, are illustrated to verify the implementation of the developed algorithms.

Mathematical Model of Universal Hypoid Generator With Supplemental Kinematic Flank Correction Motions

2000 ◽  
Vol 122 (1) ◽  
pp. 136-142 ◽  
Author(s):  
Zhang-Hua Fong
Keyword(s):  
Mathematical Model ◽  
Computer Program ◽  
Computer Programming ◽  
Object Oriented ◽  
Face Milling ◽  
Helical Motion ◽  
Hypoid Gear ◽  
Hypoid Gears ◽  
The Face ◽  
Spiral Bevel

A mathematical model of universal hypoid generator is proposed to simulate virtually all primary spiral bevel and hypoid cutting methods. The proposed mathematical model simulates the face-milling, face-hobbing, plunge cutting, and bevel-worm-shaped hobbing processes with either generating or nongenerating cutting for the spiral bevel and hypoid gears. The supplemental kinematic flank correction motions, such as modified generating roll ratio, helical motion, and cutter tilt are included in the proposed mathematical model. The proposed mathematical model has more flexibility in writing computer program and appropriate for developing the object oriented computer programming. The developed computer object can be repeatedly used by various hypoid gear researchers to reduce the effort of computer coding. [S1050-0472(00)01201-0]

Research on the cutting dynamics for face-milling of spiral bevel gears

2021 ◽  
Vol 153 ◽  
pp. 107488
Author(s):  
Fangyan Zheng ◽  
Xinghui Han ◽  
Hua Lin ◽  
Wanhua Zhao
Keyword(s):  
Face Milling ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Spiral Bevel
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