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Research Papers

Manufacture of Optimized Face-Hobbed Spiral Bevel Gears on Computer Numerical Control Hypoid Generator

[+] Author and Article Information
Vilmos V. Simon

Budapest University of Technology
and Economics,
Faculty of Mechanical Engineering,
Department for Machine Design,
H-1111 Budapest, Műegyetem rkp. 3, Hungary
e-mail: simon.vilmos@gt3.bme.hu

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 11, 2013; final manuscript received February 5, 2014; published online March 26, 2014. Assoc. Editor: Eric R. Marsh.

J. Manuf. Sci. Eng 136(3), 031008 (Mar 26, 2014) (9 pages) Paper No: MANU-13-1159; doi: 10.1115/1.4026820 History: Received April 11, 2013; Revised February 05, 2014

In this study, a method is proposed for the advanced manufacture of face-hobbed spiral bevel gears on CNC hypoid generators with optimized tooth surface geometry. An optimization methodology is applied to systematically define optimal head-cutter geometry and machine tool settings to introduce optimal tooth modifications. The goal of the optimization is to simultaneously minimize tooth contact pressures and angular displacement error of the driven gear (the transmission error). The optimization is based on machine tool setting variation on the cradle-type generator conducted by optimal polynomial functions. An algorithm is developed for the execution of motions on the CNC hypoid generator using the relations on the cradle-type machine. Effectiveness of the method was demonstrated by using a face-hobbed spiral bevel gear example. Significant reductions in the maximum tooth contact pressure and in the transmission errors were obtained.

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Figures

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Fig. 2

Relative position of the head-cutter to the imaginary generating crown gear

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Fig. 1

Concept of spiral bevel gear hobbing

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Fig. 4

Machine-tool setting for pinion tooth-surface finishing on CNC generator

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Fig. 6

Tooth contact pressure distributions along the potential contact lines when the pinion tooth is manufactured by optimized head-cutter and machine tool settings

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Fig. 3

Head-cutter blade profiles: (a) Straight lined, (b) consisting of two circular arcs

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Fig. 5

Tooth contact pressure distributions along the potential contact lines when the pinion and gear tooth surfaces are fully conjugate

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Fig. 7

Motion graphs for the CNC hypoid generator for finishing the pinion in function of the rotation angle of the head-cutter on the cradle-type generator

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Fig. 8

Motion graphs for the CNC hypoid generator for finishing the pinion in function of the rotation angle of the crown gear on the cradle-type generator

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Fig. 9

Motion graphs for the CNC hypoid generator for finishing the pinion in function of the rotation angle of the head-cutter on the CNC generator

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Fig. 10

Motion parameter differences caused by the optimal variation of the modified roll in pinion tooth flank generation

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