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Research Papers

Generation of Noncircular Spiral Bevel Gears by Face-Milling Method

[+] Author and Article Information
Fangyan Zheng

School of Automotive Engineering,
Hubei Key Laboratory of Advanced Technology
of Automotive Parts,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: 382280761@qq.com

Lin Hua

School of Automotive Engineering,
Hubei Key Laboratory of Advanced Technology
of Automotive Parts,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: hualin@whut.edu.cn

Dingfang Chen

School of Logistics Engineering,
Wuhan University of Technology,
Wuhan 430063, China
e-mail: cadcs@126.com

Xinghui Han

School of Automotive Engineering,
Hubei Key Laboratory of Advanced Technology
of Automotive Parts,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: hanxinghuihlp@126.com

Manuscript received November 22, 2015; final manuscript received February 25, 2016; published online June 24, 2016. Assoc. Editor: Xiaoping Qian.

J. Manuf. Sci. Eng 138(8), 081013 (Jun 24, 2016) (12 pages) Paper No: MANU-15-1601; doi: 10.1115/1.4033045 History: Received November 22, 2015; Revised February 25, 2016

Noncircular bevel gears are applied in variable-speed transmissions with intersecting axes. Since dedicated machines for manufacturing noncircular bevel gears are not available, noncircular bevel gears are normally manufactured using universal computer numerically controlled (CNC) machining centers, resulting in poor productivity. This paper describes a face-milling method for generation of noncircular spiral bevel gears, which is analogous to the generation of spiral bevel and hypoid gears using CNC hypoid gear generators, such as Gleason free-form hypoid generators. As a result, the productivity is significantly improved. Based on the theory of gearing, this paper first describes the basic concept of generation of conjugate noncircular spiral bevel gears. Generation of the tooth surfaces using crown-gear generation concept is analytically discussed with association to the face-milling process of generation of the proposed noncircular spiral bevel gears. The tooth surface geometries are represented by the position vectors and normals. The kinematical model of free-form machines is developed. The machine motion parameters are determined based on the theoretically defined tooth surfaces using the crown-gear generation concept. The developed method is verified by manufacturing a real pair of noncircular spiral bevel gears with satisfactory contact patterns which agree well with those modeled using a commercial cae software program.

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Figures

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Fig. 1

Crown-gear (planar generator) generation concept

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Fig. 2

Face-milling using a flat-top generator

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Fig. 3

Tooth surfaces with circular tooth line formed by flat-top generator

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Fig. 4

Coordinate system (a) and tooth surfaces (b) of cutter

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Fig. 5

Cradle location of the cutter head for a left-hand gear (a) and right-hand gear (b)

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Fig. 6

Basic cones of a noncircular bevel gear

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Fig. 7

Conjugating noncircular pitch cones

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Fig. 8

Applied coordinate systems in generating a noncircular spiral bevel gear

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Fig. 9

A model of six-axis CNC bevel gear generating machine

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Fig. 10

Coordinate relation of machine axes in the machine plane

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Fig. 11

Top-view of machine coordinates

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Fig. 12

Coordinate relation between A-axis and B-axis

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Fig. 13

Dimensionless acceleration in design

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Fig. 14

Three-dimensional models of the pinion (a) and the gear (b)

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Fig. 15

Bearing contact on the pinion (a) and the gear (b) tooth surfaces

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Fig. 16

Manufacturing process for the pinion (a) and the gear (b)

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Fig. 17

Finished pinion (a) and gear (b)

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Fig. 18

Contact patterns in the rolling experiment

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