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Research Papers

An Investigation of Root Stresses of Hypoid Gears with Misalignments

[+] Author and Article Information
M. A. Hotait1

Graduate Research Associatehotait.1@osu.edu

A. Kahraman

Professor and Director Fellow ASME e-mail: kahraman.1@osu.edu The Gear and Power Transmission Research Laboratory, Department of Mechanical Engineering,  The Ohio State University, 201 West 19th Avenue, Columbus, OH 43210

T. Nishino

Manager Mazda Motor Corporation, Hiroshima, Japannishino.t@mazda.co.jp

1

Corresponding author.

J. Mech. Des 133(7), 071006 (Jul 08, 2011) (9 pages) doi:10.1115/1.4004224 History: Received November 01, 2010; Revised May 05, 2011; Published July 07, 2011; Online July 08, 2011

In this study, the impact of misalignments on root stresses of hypoid gear sets is investigated experimentally and theoretically. An experimental set-up designed to allow operation of a hypoid gear pair under loaded quasi-static conditions with various types of tightly controlled misalignments is introduced. These misalignments include the position errors (V and H) of the pinion along the vertical and horizontal directions, the position error (G) of the gear along its axis, and the angle error (γ) between the two gear axes. For example, face-hobbed hypoid gear pair from an automotive axle application is instrumented via a set of strain gauges positioned at the roots along the faces of multiple teeth to measure root strains within a range of input torque. These root strain measurements at different V, H, G, and γ values are presented. A computational model is also proposed to predict the root stresses of face-milled and face-hobbed hypoid gear pairs under various loading and misalignment conditions. The model employs an automated finite elements mesh generator based on a predefined template for a general and computationally efficient treatment of the problem. Model predictions are compared to measurements at the end to assess the accuracy of the model and describe the measured sensitivities.

Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 2

(a) Strain-gauged hypoid gear and (b) nomenclature of the gauges

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Figure 3

Strain gauge data acquisition set-up

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Figure 4

(a) Face-milling and (b) face-hobbing cutting processes

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Figure 5

Cradle-based hypoid generator [30]

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Figure 6

(a) Position of the blade on cutter head, (b) 3D geometry of the blade, and (c) the shape of the cutting edge [27,30]

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Figure 7

Definition of the blank

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Figure 12

(a) Measured and (b) predicted stress time histories for a set of five gauges along the face width for no misalignments at an input torque of 300 Nm

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Figure 13

Examples of root stresses measured by gauges Eh, C, and At for the gear pair having different V, H, G, and γ errors. Input torque is 300 Nm.

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Figure 14

Measured peak-to-peak root stress amplitudes as a function of (a) the V error, (b) the H error, (c) the G error, and (d) the γ error. Input torque is 300 Nm.

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Figure 1

(a) Hypoid gear test machine and (b) gauges designed to induce H, V, G, and γ errors

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Figure 16

Maximum and minimum peak stresses along the face width, measurements versus model for different V errors. Input torque is 300 Nm.

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Figure 15

Predicted peak-to-peak root stress amplitudes as a function of (a) the V error and (b) the G error. Input torque is 300 Nm.

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Figure 11

(a) Load distribution along the contact lines and (b) loaded FE nodes

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Figure 10

FE models of (a) a six-tooth gear segment and (b) a six-tooth pinion segment

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Figure 9

(a) Coordinate transformation, (b) mesh template, and (c) resultant meshes

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Figure 8

(a) Pinion concave side surface and (b) mating gear convex side surface

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