Multi-objective optimization of the manufacture of face-milled hypoid gears on numerical controlled machine tool

A new method is presented for advanced manufacture of hypoid gears on numerical controlled machine tool. The tool geometry and machine tool settings are determined to introduce the optimal tooth modifications into the teeth of hypoid gears. The goal is to reduce the maximum tooth contact stresses, angular displacement error of the driven gear, and energy losses in the oil film existing between tooth surfaces. The calculation is based on the optimal variation of machine tool settings on the classical machine tool for hypoid gear manufacture. The novelty of the method is that during the machining process of teeth surfaces, the variation of machine tool settings on the cradle-type hypoid generator is conducted by polynomial functions of fifth-order. By an algorithm, this variation of machine tool settings is transferred to the numerical controlled machine tool for hypoid gear manufacture (hypoid generator). The obtained results have shown that by applying the optimal manufacture process, considerable reductions in tooth contact stresses and angular displacement errors of the driven gear, and a moderate reduction in energy losses were obtained. Therefore, by applying this new method in practice, advanced manufacture of hypoid gears on CNC hypoid generator is made possible, resulting improved operating characteristics of the hypoid gear pair.

An Accurate Method for Calculating Load Distribution Factor Kβ of Involute Gears

A new method is given to determine the load distribution factor Kβ of involute gears. Compared with the old method, the new one gives up some improper assumptions such as linear load distribution along gear tooth width. While considering the effects of bearing deformations, gear manufacture and assembly errors, gear axial force and gear tooth run-in on Kβ, the paper calculates Kβ according to “Load- Deformation Coordination” of gear tooth. Practical examples show that this method is more accurate, more effective than old ones.

Powder Metallurgy

Powder metallurgy (P/M) is a flexible metalworking process for the production of gears. The P/M process is capable of producing close tolerance gears with strengths to 1240 MPa at economical prices in higher volume quantities. This chapter discusses the capabilities, limitations, process advantages, forms, tolerances, design, tooling, performance, quality control, and inspection of P/M gear manufacture. In addition, it presents examples that illustrate the versatility of the P/M process for gear manufacture.