A new geometry definition and generation method for a face gear meshed with a spur pinion

Abstract

The conventional tooth surface of a face gear is difficult to manufacture, and the cutter for the face gear cutting is not uniform even though the parameters of the pinion mating with the face gear slightly change. Based on the analysis of the geometry features of the tooth surface, a new developable ruled surface is defined as the tooth flank of the face gear, for which the most important geometry feature is that the flank could be represented by a family of straight lines, hence it could be generated by a straight-edged cutter. The mathematical models of the new ruled tooth surface, the cutter and the generation method are presented, the deviation between the ruled surface and the conventional surface, the correction of the ruled surface to reduce the deviation are investigated through numerical examples. The manufacturing process is simulated by VERICUT software, and the results demonstrate that even when the principle deviation is added to the machined deviation, the absolute deviation is on the micro-scale. The meshing and contact simulation shows that the new surface could obtain good meshing performance when the number of face gear teeth is greater than three times the number of pinion teeth. This research provides a new method for manufacturing face gears.

Computerized Generation and Surface Deviation Correction of Ruled Surface for Face Gear Drives

“…However, this idea can lead to high cost or low efficiency in face gear machining. Peng [24] proposed that if the tooth surface of a face gear is directly regarded as a ruled surface, that is, a regular surface formed by a cluster of straight lines, its machining efficiency will be improved, and the machining cost will be reduced, which is conducive to the promotion and application of face gears. Hu [25] studied a simplified mathematical model of a new developed curve-face gear, and analyzed the compound transmission characteristics.…”

Face gear drive manufacturing: Pinion/cutter design for a crowned contact pattern

“…Wang et al 19 use laser cladding as the first step, followed by final grinding of the face gear geometry. Peng 20 presents a method for defining and generating face gear geometries with a straight-edged cutter.…”

Machining principle and cutter design of face gear skiving

“…Many scholars have carried out a lot of research on face gear, especially in processing. [8][9][10] Litvin's group carried out systematic and comprehensive research on face gear drive. 1,2 Zschippang analyzed the tooth surface generation and contact characteristics of face gear.…”

“…Based on the principle of meshing, Tang and Yang 8 proposed a planning method for machining spur gears with a four-axis CNC planer and used simulation software to verify the feasibility of the method. Based on the analysis of the features of the tooth surface, Peng 9 proposed a method for determining the tooth surface of a face gear with a straight-edged tool. Wang et al 10 presents a generating milling method for the spur face gear using a five-axis computer numerical control milling machine and proposes a milling principle of the spur face gear using a milling cutter, and carried out the face gear milling experiment on the self-developed milling machine.…”