Cutter Head Approximation Machining Method of Line Contact Spiral Bevel Gear Pairs Based On Controlling Topological Deviations

To improve the meshing performance and increase the bearing capacity and service life of spiral gear pairs, the cutter head approximation machining method based on controlling topological deviations was proposed to solve the problem where line contact spiral bevel gears with tapered teeth depth cannot be directly machined by cutter heads. First, the mathematical model of line contact conjugate flanks was established, and meshing equations and conjugate flank equations of bevel gear pairs were derived. Second, the gear tooth flank was set as the datum tooth flank for priority machining, and the pinion theoretical tooth flank which is fully conjugate with the gear tooth flank and the pinion machining tooth flank matching with the gear were solved. Then, the geometric topological deviations model of the comparison between the pinion machining tooth flank and its theoretical tooth flank can be established. Finally, with the pinion machining tooth flank approaching its theoretical tooth flank as the modification, the additional cutting motions and machining compensation parameters of cutter heads were obtained to control the pinion machining tooth flank deviations and reduce them to the allowable deviations of its theoretical tooth flank. The contact simulation analysis and rolling test verified the correctness of the line contact conjugate flank model and feasibility of the cutter head approximation machining method.