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Research Papers

Tooth Surface Error Correction for Face-Hobbed Hypoid Gears

[+] Author and Article Information
Qi Fan

F Gleason Works, 1000 University Avenue, Rochester, NY 14692qfan@gleason.com

J. Mech. Des 132(1), 011004 (Dec 17, 2009) (8 pages) doi:10.1115/1.4000646 History: Received June 24, 2009; Revised November 04, 2009; Published December 17, 2009; Online December 17, 2009

Face-hobbing is a continuous generating process employed in manufacturing spiral bevel and hypoid gears. Due to machining dynamics and tolerances of machine tools, the exact tooth surface geometry may not be obtained from the machining process using theoretical machine tool settings. Repeatable tooth surface geometric errors may be observed. The tooth surface errors will cause unfavorable displacement of tooth contact and increased transmission errors, resulting in noisy operation and premature failure due to edge contact and highly concentrated stresses. In order to eliminate the tooth surface errors and ensure precision products, a corrective machine setting technique is employed to modify the theoretical machine tool settings, compensating for the surface errors. This paper describes a method of correcting tooth surface errors for spiral bevel and hypoid gears generated by the face-hobbing process using computer numerically controlled hypoid gear generators. Polynomial representation of the universal motions of machine tool settings is considered. The corrective universal motion coefficients are determined through an optimization process with the target of minimization of the tooth surface errors. The sensitivity of the changes of the tooth surface geometry to the changes of universal motion coefficients is investigated. A numerical example of a face-hobbed hypoid pinion is presented.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Indexing motion of face-hobbing

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Figure 2

Concave and convex tooth surfaces

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Figure 3

Four sections of blades

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Figure 4

Lines of generating roll

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Figure 5

Definition of tooth flank grid

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Figure 6

Coordinate system S(X,Y,δ)

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Figure 7

Original error surfaces before correction

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Figure 8

Error surfaces after first order correction

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Figure 9

Error surfaces after higher order correction

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