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RESEARCH PAPERS

Helical Gears, Effects of Tooth Deviations and Tooth Modifications on Load Sharing and Fillet Stresses

[+] Author and Article Information
Raynald Guilbault

Department of Mechanical Engineering, Ecole de technologie superieure, Montreal, H3C 1K3, Canadaraynald.guilbault@etsmtl.ca

Claude Gosselin, Louis Cloutier

Department of Mechanical Engineering, Laval University, Québec, G1K 7P4, Canada

J. Mech. Des 128(2), 444-456 (May 26, 2005) (13 pages) doi:10.1115/1.2167650 History: Received November 08, 2004; Revised May 26, 2005

Based on a few specific cases, this paper presents a comparative investigation of the effect of helix slope and form deviation tolerances as specified by grades 5 and 7 of the ANSI/AGMA ISO 1328-1 Standard for Cylindrical Gears. In addition, the consequences of longitudinal flank crowning and radial tip relief modifications are investigated, as applied on a misaligned helical gear set. For all simulations, the express model (Guilbault, 2005, ASME J. Mech. Des., 127(6), pp. 1161–1172) is employed. The bending deflection and fillet stresses are obtained from a combination of finite strip and finite difference meshes. The rolling-sliding motion of mating gear teeth is modeled with a cell discretization of the contact area, which offers fast and accurate results. Similar contact conditions arise from a helix slope deviation or a misalignment of the gear set: the first contact point is driven to a theoretical contact line endpoint. Such a condition produces a localized, and clearly impaired, contact area subject to overloading. Consequently, flank crowning and tip relief corrections must be carefully regarded in the design process. The presented results highlight that, if improperly combined, profile modifications can amplify the overloading condition.

Copyright © 2006 by American Society of Mechanical Engineers
Topics: Stress , Gears , Pressure
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References

Figures

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Figure 1

Displacement-stress model of a helical gear tooth

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Figure 2

Pressure cells in contact plane

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Figure 3

Flowchart of the express model

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Figure 4

Contact lines for the meshing position considered

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Figure 5

Simulation domain and studied points

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Figure 6

Pressure distributions on contact plane—no helix slope deviation

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Figure 7

Pressure distributions on contact plane—case A, grade 5

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Figure 8

Pressure distributions on contact plane—case A, grade 7

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Figure 9

Pressure distributions on contact plane—case B, grade 5

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Figure 10

Pressure distributions on contact plane—case B, grade 7

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Figure 11

Load distributions on contact lines, theoretical teeth, grades 5 and 7 with positive and negative helix slope deviations

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Figure 12

Maximum principal pinion tooth fillet stress distributions, no deviation

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Figure 13

Maximum principal pinion fillet stress distributions—case A, grade 5

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Figure 14

Maximum principal pinion tooth fillet stress distributions—case A, grade 7

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Figure 15

Maximum principal pinion tooth fillet stress distributions—case B, grade 5

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Figure 16

Maximum principal pinion fillet stress distributions—case B, grade 7

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Figure 17

Helix form deviation

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Figure 18

Pressure distributions in the contact plane—grade 5

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Figure 19

Pressure distributions in the contact plane—grade 7

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Figure 20

Load distributions on simultaneous contact lines (unmodified teeth and grades 5 and 7 with undulated profiles)

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Figure 21

Maximum principal pinion fillet stress distributions—grade 5, deviated tooth

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Figure 22

Maximum principal pinion fillet stress distributions—grade 7, deviated tooth

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Figure 23

Crowning modification

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Figure 24

Modified rack cutter profile

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Figure 25

Pressure distributions on the contact plane—unmodified, misaligned gear set

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Figure 26

Pressure distributions on the contact plane—crowned, misaligned gear set

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Figure 27

Pressure distributions on the contact plane—tip relieved, misaligned gear set

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Figure 28

Pressure distributions on the contact plane—crowned and tip relieved, misaligned gear set

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Figure 29

Path of overloading along tooth edges

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Figure 30

Load distributions on simultaneous contact lines of misaligned sets

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Figure 31

Maximum principal pinion fillet stress distributions—original, misaligned gear set

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Figure 32

Maximum principal pinion fillet stress distributions—crowned, misaligned gear set

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Figure 33

Maximum principal pinion fillet stress distributions—tip relieved, misaligned gear set

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Figure 34

Maximum principal pinion fillet stress distributions— crowned and tip-relieved, misaligned gear set

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