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Research Papers: Design of Direct Contact Systems

Manufacturing Process for a Face Gear Drive With Local Bearing Contact and Controllable Unloaded Meshing Performance Based on Ease-Off Surface Modification

[+] Author and Article Information
Xian-long Peng

School of Mechanical Engineering,
Xi'an University of Science and Technology,
Xi'an, Shaanxi 710054, China
e-mails: pxljsh@126.com; pxljsh@xust.edu.cn

Le Zhang

School of Mechanical Engineering,
Xi'an University of Science and Technology,
Xi'an, Shaanxi 710054, China
e-mail: 674184809@qq.com

Zong-de Fang

School of Mechanical Engineering,
Northwestern Polytechnical University,
Xi'an, Shaanxi 710072, China
e-mail: fauto@nwpu.edu.cn

1Corresponding author.

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received July 15, 2015; final manuscript received December 27, 2015; published online February 23, 2016. Assoc. Editor: Hai Xu.

J. Mech. Des 138(4), 043302 (Feb 23, 2016) (13 pages) Paper No: MD-15-1501; doi: 10.1115/1.4032579 History: Received July 15, 2015; Revised December 27, 2015

A manufacturing process for fabricating ease-off surfaces of a face gear drive that is provided with controllable unloaded meshing performance and local bearing contact is proposed. In order to control the unloaded meshing performance, a predesigned transmission error, a predesigned contact path, and the length of contact ellipse are applied in the redesign of the ease-off surfaces of the pinion and face gear. A method of point contact between the grinding disk and the manufactured pinion is proposed to generate the pinion's ease-off surface, the grinding disk is driven by a series of parabolic motions. Numerical examples are used to illustrate the application of the proposed method, the proposed method is proven to be feasible, and the redesigned face gear is proven to be able reproduce the predesigned unloaded meshing performance simulated by tooth contact analysis (TCA). The influence of misalignment on unloaded meshing performance is also analyzed.

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Figures

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Fig. 1

Simulation of a pinion meshing with a face gear

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Fig. 2

A fourth-order polynomial function of transmission errors

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Fig. 3

Coordinate systems applied in the generation of surface Σ2

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Fig. 4

Predesigned contact path on surface Σ2r

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Fig. 5

Determination of points Pi3, Pi4 to define the ease-off surface of the pinion: (a) determination of points Pi1, bi1, ai1, Pi3, (b) illustration of points Pi, ai1, ai2, and (c) ease-off topography and Pi Pi3Pi4

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Fig. 6

k′k′ using in definition of ease-off topography Σ1r

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Fig. 7

Material needing cutting for surface Σ1r

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Fig. 8

Manufacturing of the pinion with ease-off topography Σ1r: (a) freedom of motion of the disk Σg, (b) definition of surface Σg, and (c) coordinate systems in generation of Σ1r

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Fig. 10

The transmission errors: (a) in case 1 and (b) in case 2

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Fig. 11

Ease-off topography Σ2r of the face gear: (a) case 1 and (b) case 2

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Fig. 12

Coefficients c1, c2, c3 of machine settings in case 1

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Fig. 13

Ease-off topography Σ1r of the pinion: (a) case 1 and (b) case 2

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Fig. 14

Influence of misalignment on the length of the contact ellipse in case 1: (1) no misalignments, (2) predesigned length, (3) Δq = 0.2 mm, (4) ΔE = 0.3 mm, and (5) Δγ = 0.02 deg

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Fig. 15

Influence of misalignment on the length of the contact ellipse in case 2

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Fig. 16

The influence of the misalignment on the shift of the contact path: (a) case 1 and (b) case 2

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Fig. 17

The influence of the misalignment on the GTE: (a) the GTE shape change in case 1, (b) the GTE shape change in case 2, (c) the angle at the GTE peak in case 1, and (d) the angle at the GTE peak in case 2

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