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

Abstract

In order to solve the problems of low efficiency and complex cutting tools in conventional face gear machining, this paper presents a machining method of ruled surface face gears with conical cutters and proposes a new pinion to correct deviation and its machining method. Firstly, the mathematical models of ruled surface face gears and conical cutters are established, the motion rules of the conical cutter are derived, and the influence of basic parameters on the tooth surface deviation between ruled surface and conventional surface is analyzed. Secondly, for the sake of correction of tooth surface deviation, reverse conjugation is applied to the ruled surface to obtain a corrected pinion. On the basis of hobbing cylindrical gears, the purpose of machining corrected pinions is achieved by increasing CNC motions. Finally, the manufacturing process is simulated by VERICUT software, the results demonstrate that the machining error of ruled surface and pinion do not exceed 10 μm, and through LTCA, the meshing performance of the ruled surface face gear pair is basically the same as that of conventional face gear pair, proving the feasibility of replacing the latter with the former. This study provides a new manufacturing method for face gears.