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Research Papers

Optimal Tooth Modifications in Face-Hobbed Spiral Bevel Gears to Reduce the Influence of Misalignments on Elastohydrodynamic Lubrication

[+] Author and Article Information
Vilmos V. Simon

Budapest University of Technology
and Economics,
Faculty of Mechanical Engineering,
Department for Machine Design,
H-1111 Budapest, Műegyetem rkp. 3, Hungary
e-mail: simon.vilmos@gt3.bme.hu

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received April 4, 2013; final manuscript received December 5, 2013; published online April 28, 2014. Assoc. Editor: Zhang-Hua Fong.

J. Mech. Des 136(7), 071007 (Apr 28, 2014) (9 pages) Paper No: MD-13-1151; doi: 10.1115/1.4026264 History: Received April 04, 2013; Revised December 05, 2013

In this study, an optimization methodology is proposed to systematically define the optimal tooth modifications introduced by head-cutter geometry and machine-tool settings to minimize the influence of misalignments on the elastohydrodynamic (EHD) lubrication characteristics in face-hobbed spiral bevel gears. The goal is to simultaneously maximize the EHD load-carrying capacity of the oil film and to minimize power losses in the oil film when different misalignments are inherent in the gear pair. The proposed optimization procedure relies heavily on the EHD lubrication analysis developed in this paper. The core algorithm of the proposed nonlinear programming procedure is based on a direct search method. Effectiveness of this optimization was demonstrated on a face-hobbed spiral bevel gear example. A drastic increase in the EHD load-carrying capacity of the oil film and a reduction in the power losses in the oil film were obtained.

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Figures

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Fig. 1

Head-cutter blade profiles

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Fig. 2

Concept of spiral bevel gear hobbing

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Fig. 3

Relative position of the head-cutter to the imaginary generating crown gear

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Fig. 4

Relative position of the pinion and the gear in mesh

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Fig. 5

Pressure distribution in the oil film for the basic values of the machine-tool setting parameters

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Fig. 6

Pressure distribution in the oil film for the optimal values of the machine-tool setting parameters

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Fig. 7

The influence of pinion offset (Δa) on maximum tooth contact pressure (pmax) and temperature (Tmax), EHD load-carrying capacity (W), and friction factor (fT)

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Fig. 8

The influence of the axial position error of the pinion Δb on maximum tooth contact pressure (pmax) and temperature (Tmax), EHD load-carrying capacity (W), and friction factor (fT)

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Fig. 9

The influence of the angular misalignment in the horizontal plane of the pinion axis (ɛh) on maximum tooth contact pressure (pmax) and temperature (Tmax), EHD load-carrying capacity (W), and friction factor (fT)

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Fig. 10

The influence of the angular misalignment in the vertical plane of the pinion axis (ɛv) on maximum tooth contact pressure (pmax) and temperature (Tmax), EHD load-carrying capacity (W), and friction factor (fT)

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