Simulation based Approach to Study the Effect of Hypoid Gear Manufacturing Variability on In-Cabin Noise

2021 ◽  
Author(s):  
Kalyan Deepak Kolla ◽  
Ketan Paua ◽  
Rajkumar Bhagate ◽  
Vikraman Vellandi ◽  
Saurabh Kumar Jain
Keyword(s):  
Hypoid Gear ◽  
Cabin Noise ◽  
Simulation Based ◽  
Gear Manufacturing

Cutter Interchangeability for Spiral-Bevel and Hypoid Gear Manufacturing

2003 ◽  
Author(s):  
Claude Gosselin ◽  
Jack Masseth ◽  
Wei Liang
Keyword(s):  
Test Case ◽  
Hypoid Gear ◽  
Hypoid Gears ◽  
Manufacturing Operations ◽  
Before And After ◽  
Gear Manufacturing ◽  
Spiral Bevel ◽  
Tooth Flank ◽  
Tooth Flank Surface Topography ◽  
Flank Surface

In the manufacturing of spiral-bevel and hypoid gears, circular cutter dimensions are usually based on the desired performance of a gear set. In large manufacturing operations, where several hundred gear geometries may have been cut over the years, the necessary cutter inventory may become quite large since the cutter diameters will differ from one geometry to another, which results in used storage space and associated costs in purchasing and maintaining the cutter parts. Interchangeability of cutters is therefore of significant interest to reduce cost while maintaining approved tooth geometries. An algorithm is presented which allows the use of a different cutter, either in diameter and/or pressure angle, to obtain the same tooth flank surface topography. A test case is presented to illustrate the usefulness of the method: the OB cutter diameter of an hypoid pinion is changed from 8.9500" to 9.1000". CMM results and the comparison of the bearing patterns before and after change show excellent correlation, and indicate that the new pinion can be used in place of the original pinion without performance or quality problems. Significant cost reductions may be obtained with the application of the method.

Influence of manufacturing error tolerances on contact pressure in gears

2020 ◽  
pp. 095440622097671
Author(s):  
Rikard Hjelm ◽  
Hans Hansson ◽  
Aylin Ahadi ◽  
Carin Andersson ◽  
Jens Wahlström
Keyword(s):  
Contact Pressure ◽  
Industrial Applications ◽  
Spur Gears ◽  
Pitch Error ◽  
Simulation Based ◽  
Manufacturing Errors ◽  
Gear Manufacturing ◽  
Parametric Description ◽  
Gear Geometry ◽  
Slope Error

Gear manufacturing always results in some degree of manufacturing errors, i.e. deviations from the desired gear geometry. These errors alter how the gears mesh, typically causing increased contact pressure which in turn shortens service life. It is therefore crucial to choose tolerances such that excessive contact pressure, and especially tip contact, is avoided. With increasing demands due to electrification, this becomes even more important. The aim of this paper is to study how pitch error and profile slope error affect the contact pressure in spur gears sets. The meshing is simulated using a novel simulation approach that uses a parametric description of the reference profile and gear geometry, and a hybrid model for the compliance. The method includes tooth modifications such as tip relief, and uses the true geometry to find contacts. Thus, it also handles contact outside the nominal line of action, including tip contact. The study includes cases where a gear is subjected to both pitch error and profile slope error simultaneously. Numerical examples, relevant to the automotive industry, show the outcome of the simulations. It is shown how simulation-based tolerances for relevant industrial applications can be used to improve manufacturing outcome.

Optimization of Pinion Roughing of Spiral Bevel and Hypoid Gear

2006 ◽  
Vol 220 (4) ◽  
pp. 483-488 ◽  
Author(s):  
J-G Li ◽  
S-M Mao ◽  
J-L He ◽  
X-T Wu
Keyword(s):  
Complex Shape ◽  
Bending Strength ◽  
Bending Stress ◽  
Hypoid Gear ◽  
Blade Profile ◽  
Hypoid Gears ◽  
Cutter Life ◽  
Gear Manufacturing ◽  
Heavy Truck ◽  
Spiral Bevel

Roughing plays a very important role in spiral bevel and hypoid gear manufacturing. The roughing machine settings and cutter blade profile are optimized in this article on the basis of three considerations: the transition between the roughing root and the finishing fillet is smoothened, which causes the gear to obtain minimum possible bending stress and maximum bending strength; the finishing stock is distributed evenly to improve the residual stress, which causes the distortion of pinion during the process of heat treatment; and the working load of finishing cutter tip is minimized, and the maximum cutter life is obtained. The complex shape method is successfully used to optimize the roughing machine settings and cutter blade profile. The advantages and benefits of the newly developed roughing process are verified in the manufacture of hypoid gears for a heavy truck axle in a Chinese vehicle company.

The Ultimate Motion Graph

1999 ◽  
Vol 122 (3) ◽  
pp. 317-322 ◽  
Author(s):  
Hermann J. Stadtfeld ◽  
Uwe Gaiser
Keyword(s):  
Dynamic Strength ◽  
Physical Effect ◽  
Hypoid Gear ◽  
Manufacturing Plants ◽  
Gear Noise ◽  
Tooth Surfaces ◽  
Gear Manufacturing ◽  
Manufacturing Tolerances ◽  
Gear Geometry ◽  
Gear Drives

The innovation was to develop a gear geometry that reduces or eliminates gear noise and increases the strength of gears. Gear noise is a common problem in all bevel and hypoid gear drives. A variety of expensive gear geometry optimizations are applied daily in all hypoid gear manufacturing plants, to reduce gear noise. In many cases those efforts have little success. Additional expensive finishing operations (lapping after the grinding) are applied to achieve the goal of quiet and stong gear sets. The ultimate motion graph is a concept for modulating the tooth surfaces that uses a physical effect to cancel out the dynamic disturbances that are naturally generated by all up-to-date known kind of gears. The ultimate motion graph also eliminates the sensitivity of gears against deflection under load or displacements because of manufacturing tolerances. Lower dynamic disturbances will also increase the dynamic strength. [S1050-0472(00)00203-8]

Identification of the Machine Settings of Real Hypoid Gear Tooth Surfaces

1998 ◽  
Vol 120 (3) ◽  
pp. 429-440 ◽  
Author(s):  
C. Gosselin ◽  
T. Nonaka ◽  
Y. Shiono ◽  
A. Kubo ◽  
T. Tatsuno
Keyword(s):  
Manufacturing Industry ◽  
Gear Tooth ◽  
Computer Software ◽  
Tooth Surface ◽  
Hypoid Gear ◽  
Gear Teeth ◽  
Tooth Surfaces ◽  
Gear Manufacturing ◽  
Pattern Development ◽  
Cutting Processes

In the spiral bevel and hypoid gear manufacturing industry, master gear sets are usually developed from initial machine settings obtained from computer software or instruction sheets. These initial machine settings are then modified until a satisfactory bearing pattern is obtained, a process called bearing pattern development. Once a satisfactory bearing pattern is obtained, manufacturing errors and heat treatment distorsions can be accounted for by proportionally changing the machine settings according to the results of a V-H test in which the pinion vertical and horizontal positions are modified until the bearing pattern is acceptable. Once a satisfactory combination of master pinion and gear is obtained, their actual tooth surfaces usually do not correspond to those of the initial theoretical model, and the theoretical pinion and gear surface definitions are unknown. This paper presents a computer algorithm used to identify the machine settings producing a theoretical tooth surface closest to that of a measured surface, what the authors call Surface Match, in order to effectively simulate the kinematical behavior of real gear teeth. The approach is applicable to both 1st and 2nd order surface errors, including profile deviation, for any cutting process. However, given the availability of experimental data for the Fixed Setting™, Formate™ and Helixform™ cutting processes, the examples presented in the paper are related to these cutting processes.

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