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RESEARCH PAPERS

Flank Modification Methodology for Face-Hobbing Hypoid Gears Based on Ease-Off Topography

[+] Author and Article Information
Yi-Pei Shih

Department of Mechanical Engineering, National Chung Cheng University, No. 168 University Road, Min-Hsiung, Chia-Yi, Taiwan 621, R.O.C.

Zhang-Hua Fong1

Department of Mechanical Engineering, National Chung Cheng University, No. 168 University Road, Min-Hsiung, Chia-Yi, Taiwan 621, R.O.C.imezhf@ccu.edu.tw

1

Corresponding author.

J. Mech. Des 129(12), 1294-1302 (Dec 30, 2006) (9 pages) doi:10.1115/1.2779889 History: Received August 13, 2006; Revised December 30, 2006

The fundamental design of spiral bevel and hypoid gears is usually based on a local synthesis and a tooth contact analysis of the gear drive. Recently, however, several flank modification methodologies have been developed to reduce running noise and avoid edge contact in gear making, including modulation of tooth surfaces under predesigned transmission errors. This paper proposes such a flank modification methodology for face-hobbing spiral bevel and hypoid gears based on the ease-off topography of the gear drive. First, the established mathematical model of a universal face-hobbing hypoid gear generator is applied to investigate the ease-off deviations of the design parameters—including cutter parameters, machine settings, and the polynomial coefficients of the auxiliary flank modification motion. Subsequently, linear regression is used to modify the tooth flanks of a gear pair to approximate the optimum ease-off topography suggested by experience. The proposed method is then illustrated using a numerical example of a face-hobbing hypoid gear pair from Oerlikon’s Spiroflex cutting system. This proposed flank modification methodology can be used as a basis for developing a general technique of flank modification for similar types of gears.

FIGURES IN THIS ARTICLE
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Copyright © 2007 by American Society of Mechanical Engineers
Topics: Gears , Design , Machinery
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Figures

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Figure 1

Coordinate systems for the left-handed face-hobbing cutter head

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Figure 2

Coordinate systems between the cutter head and the generating gear

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Figure 3

Coordinate systems between the generating gear and the work gear

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Figure 4

TCA and ease-off topography of an Oerlikon’s Spiroflex gear set with a 3.334mm module

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Figure 5

Coordinate systems between the virtual pinion cutter and the work gear

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Figure 6

Original ease-off topography of the Spiroflex hypoid gear set for the numerical example

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Figure 7

Ease-off topography of the Gleason TriAC® formate gear set based on the reconstructed surfaces

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Figure 8

Ease-off sensitivity topography corresponding to the cutter parameters for the pinion

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Figure 9

Ease-off sensitivity topography corresponding to the machine settings for the pinion

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Figure 10

Ease-off sensitivity topography corresponding to the polynomial coefficients of the modified roll motion for the pinion

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Figure 11

Simulated ease-off topography and TCA based on the flank modifications for the pinion

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Figure 12

Deviations between the modified and desired ease-off topographies

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