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Research Papers

Straight Bevel Gear Generation Using the Dual Interlocking Circular Cutter Cutting Method on a Computer Numerical Control Bevel Gear-Cutting Machine

[+] Author and Article Information
Yi-Pei Shih

Associate Professor
Department of Mechanical Engineering,
National Taiwan University of
Science and Technology,
No. 43, Sec. 4, Keelung Road,
Taipei 106, Taiwan
e-mail: shihyipei@mail.ntust.edu.tw

Hsin-Yen Hsieh

Department of Mechanical Engineering,
National Taiwan University of
Science and Technology,
No. 43, Sec. 4, Keelung Road,
Taipei 106, Taiwan

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received December 26, 2014; final manuscript received June 12, 2015; published online September 9, 2015. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 138(2), 021007 (Sep 09, 2015) (11 pages) Paper No: MANU-14-1716; doi: 10.1115/1.4030937 History: Received December 26, 2014

The dual interlocking circular cutter (DICC) cutting method, used to produce straight bevel gears (SBGs), employs two interlocked cutters to generate tooth surfaces with a combination of profile and lengthwise crowning. The gear pairs produced have the advantage of low assembly sensibility. However, the cutting method can only be carried out on a dedicated machine with complicated mechanisms, which are not only difficult to setup but also reduce stiffness and accuracy. Gleason recently applied this cutting method on the modern CNC bevel gear-cutting machine to increase productivity and accuracy in manufacturing SBGs; however, they revealed no details of this application because of commercial considerations. The main goal of this work, therefore, is to establish a mathematical model of an SBG produced by the DICC method on a virtual machine. The work gear is cut by an imaginary generating gear that enables derivation of the SBG tooth surface. Ease-off and tooth contact analysis (TCA) are applied to confirm the correctness of the proposed model. A cutting method is also proposed that can be transformed from a specific traditional machine to a modern CNC bevel gear-cutting machine. Conversion from the virtual machine enables derivation of the five-axis nonlinear machine coordinates and subsequent programming of the NC data. Finally, the correctness of NC data for machining is confirmed using the vericut nc verification software.

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References

Townsend, D. P. , 1991, Dudley's Gear Handbook, 2nd ed., McGraw-Hill, New York.
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The Gleason Works, 1961, “Calculating Instructions Generated Straight Bevel Coniflex® Gears (No. 2A, 102, 104, 114 and 134 Straight Bevel Coniflex Generators),” Rochester, NY.
Shih, Y. P. , and Fong, Z. H. , 2008, “Flank Correction for Spiral Bevel and Hypoid Gears on a Six-Axis CNC Hypoid Generator,” ASME J. Mech. Des., 130(6), p. 062604. [CrossRef]
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Shih, Y. P. , and Fong, Z. H. , 2007, “Flank Modification Methodology for Face-Hobbing Hypoid Gears Based on Ease-Off Topography,” ASME J. Mech. Des., 129(12), pp. 1294–1302. [CrossRef]
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Figures

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Fig. 1

Imaginary generating gears and work gears: (a) pinion and (b) gear

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Fig. 2

Standard imaginary generating gear

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Fig. 3

Dual interlocking circular cutters

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Fig. 5

Cutter position in the coordinate system of the generating gear

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Fig. 6

Coordinate systems between the cutter and generating gear on the virtual machine

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Fig. 7

Coordinate systems between the generating gear and work gear on the virtual machine: (a) upper position for cutting right flank, (b) lower position for cutting left flank, (c) coordinate systems for cutting right flank, and (d) coordinate systems for cutting left flank

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Fig. 8

Coordinate systems of the CNC bevel gear-cutting machine

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Fig. 9

Three-dimensional models created by solidworks

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Fig. 10

Correlation between generated lengthwise crowning and blade profile angle

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Fig. 12

TCA: (a) contact pattern and (b) transmission error

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Fig. 13

Cutting positions at the cradle angle φc=0 on the bevel gear-cutting machine: (a) right flank cutting (upper position) and (b) left flank cutting (lower position)

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Fig. 14

Cutting simulation for the pinion using vericut

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Fig. 15

Flank topographic deviations between the theoretic and produced tooth surfaces: (a) solid model (STL file) produced by vericut and (b) flank topographic deviations

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