Multi-objective optimization of the manufacture of face-milled hypoid gears on numerical controlled machine tool

Abstract

A new method is presented for advanced manufacture of hypoid gears on numerical controlled machine tool. The tool geometry and machine tool settings are determined to introduce the optimal tooth modifications into the teeth of hypoid gears. The goal is to reduce the maximum tooth contact stresses, angular displacement error of the driven gear, and energy losses in the oil film existing between tooth surfaces. The calculation is based on the optimal variation of machine tool settings on the classical machine tool for hypoid gear manufacture. The novelty of the method is that during the machining process of teeth surfaces, the variation of machine tool settings on the cradle-type hypoid generator is conducted by polynomial functions of fifth-order. By an algorithm, this variation of machine tool settings is transferred to the numerical controlled machine tool for hypoid gear manufacture (hypoid generator). The obtained results have shown that by applying the optimal manufacture process, considerable reductions in tooth contact stresses and angular displacement errors of the driven gear, and a moderate reduction in energy losses were obtained. Therefore, by applying this new method in practice, advanced manufacture of hypoid gears on CNC hypoid generator is made possible, resulting improved operating characteristics of the hypoid gear pair.

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

“…1,2 (3) Some types of gear drives do not have a standard or theoretical tooth surface, so the tooth surfaces are defined by the meshing performance. 24–26 This idea is also applicable to a face gear with a developable ruled surface. For example, the tooth surface of the pinion, which has fewer teeth and is easier to machine, could be redefined using the conjugation principle and then modified.…”

“…The crowning profile for the newly defined tooth surface is shown in Figure 8(a), wherein a p is the parabola coefficient in the profile direction, u a0 is used to control the position of the parabola vertex, and the vector R a in equation ( 15) is replaced with equation (26). Figure 8(b) shows the longitudinal crowning, wherein a l is the parabola coefficient of the plunging trajectory of the coordinate origin O b and L b0 is the distance from the coordinate origin O 2 to the parabola vertex, which determines the position of the longitudinal parabola vertex.…”

Optimization design of load-sharing and light weight of the twin rotors concentric face gear power-split transmission system based on gear tooth matching condition

“…Marjanovic et al 21 introduced the characteristics and problems of gear system optimization with spur gears, provided the best concept selection description based on the selection matrix, the best material selection, the best gear ratio and the best position, further introduced the definition of mathematical model, and used the original software to optimize the gear system with spur gears. Simon 22 proposed a new method for advanced manufacturing of hypoid gears on CNC machine tools. Determine the tool geometry and machine settings to introduce the optimal tooth shape modification into the teeth of the hypoid gear.…”

Reverse-adjustment algorithm of tooth surface precision control design for spiral bevel gears

“…Transferring machine configuration changes to CNC machines for hypoid gear machining allows for advanced manufacture of curved bevel gears. 13 Mu et al 14 proposed a design method of high-coincidence spiral bevel gears based on functional-oriented design of high-order transmission error (HTE). According to the designed HTE curve and contact path, the target tooth surface of the pinion can be obtained by modifying the conjugate tooth surface derived from the meshing gear.…”