The Ultimate Motion Graph

1999 ◽  
Vol 122 (3) ◽  
pp. 317-322 ◽  
Author(s):  
Hermann J. Stadtfeld ◽  
Uwe Gaiser
Keyword(s):  
Dynamic Strength ◽  
Physical Effect ◽  
Hypoid Gear ◽  
Manufacturing Plants ◽  
Gear Noise ◽  
Tooth Surfaces ◽  
Gear Manufacturing ◽  
Manufacturing Tolerances ◽  
Gear Geometry ◽  
Gear Drives

The innovation was to develop a gear geometry that reduces or eliminates gear noise and increases the strength of gears. Gear noise is a common problem in all bevel and hypoid gear drives. A variety of expensive gear geometry optimizations are applied daily in all hypoid gear manufacturing plants, to reduce gear noise. In many cases those efforts have little success. Additional expensive finishing operations (lapping after the grinding) are applied to achieve the goal of quiet and stong gear sets. The ultimate motion graph is a concept for modulating the tooth surfaces that uses a physical effect to cancel out the dynamic disturbances that are naturally generated by all up-to-date known kind of gears. The ultimate motion graph also eliminates the sensitivity of gears against deflection under load or displacements because of manufacturing tolerances. Lower dynamic disturbances will also increase the dynamic strength. [S1050-0472(00)00203-8]

An Approach for Determination of Basic Machine-Tool Settings From Blank Data in Face-Hobbed and Face-Milled Hypoid Gears

2015 ◽  
Vol 137 (9) ◽  
Author(s):  
Ignacio Gonzalez-Perez ◽  
Alfonso Fuentes ◽  
Ramon Ruiz-Orzaez
Keyword(s):  
Machine Tool ◽  
Normal Pressure ◽  
Hypoid Gear ◽  
Hypoid Gears ◽  
Gear Teeth ◽  
Gear Drive ◽  
Gear Geometry ◽  
Gear Drives ◽  
Crown Gear

The conditions of meshing and contact in hypoid gear drives depend substantially on the machine-tool settings to be applied. Determination of gear geometry is the first step in the design process of a hypoid gear drive. An approach for determination of basic machine-tool settings for face-hobbed and face-milled hypoid gears is proposed, covering the cases when the gear is generated and nongenerated. Gear basic machine-tool settings are determined from the blank data that can be obtained from application of Standard ANSI/AGMA 2005-C96. Some machine-tool settings are determined analytically considering the imaginary generation of the gear by a crown gear. Some other machine-tool settings are obtained numerically in order to provide some given blank data as the normal chordal tooth thickness and the normal pressure angles of the gear teeth. The developed theory is illustrated with numerical examples.

Identification of the Machine Settings of Real Hypoid Gear Tooth Surfaces

1998 ◽  
Vol 120 (3) ◽  
pp. 429-440 ◽  
Author(s):  
C. Gosselin ◽  
T. Nonaka ◽  
Y. Shiono ◽  
A. Kubo ◽  
T. Tatsuno
Keyword(s):  
Manufacturing Industry ◽  
Gear Tooth ◽  
Computer Software ◽  
Tooth Surface ◽  
Hypoid Gear ◽  
Gear Teeth ◽  
Tooth Surfaces ◽  
Gear Manufacturing ◽  
Pattern Development ◽  
Cutting Processes

In the spiral bevel and hypoid gear manufacturing industry, master gear sets are usually developed from initial machine settings obtained from computer software or instruction sheets. These initial machine settings are then modified until a satisfactory bearing pattern is obtained, a process called bearing pattern development. Once a satisfactory bearing pattern is obtained, manufacturing errors and heat treatment distorsions can be accounted for by proportionally changing the machine settings according to the results of a V-H test in which the pinion vertical and horizontal positions are modified until the bearing pattern is acceptable. Once a satisfactory combination of master pinion and gear is obtained, their actual tooth surfaces usually do not correspond to those of the initial theoretical model, and the theoretical pinion and gear surface definitions are unknown. This paper presents a computer algorithm used to identify the machine settings producing a theoretical tooth surface closest to that of a measured surface, what the authors call Surface Match, in order to effectively simulate the kinematical behavior of real gear teeth. The approach is applicable to both 1st and 2nd order surface errors, including profile deviation, for any cutting process. However, given the availability of experimental data for the Fixed Setting™, Formate™ and Helixform™ cutting processes, the examples presented in the paper are related to these cutting processes.

Cutter Interchangeability for Spiral-Bevel and Hypoid Gear Manufacturing

2003 ◽  
Author(s):  
Claude Gosselin ◽  
Jack Masseth ◽  
Wei Liang
Keyword(s):  
Test Case ◽  
Hypoid Gear ◽  
Hypoid Gears ◽  
Manufacturing Operations ◽  
Before And After ◽  
Gear Manufacturing ◽  
Spiral Bevel ◽  
Tooth Flank ◽  
Tooth Flank Surface Topography ◽  
Flank Surface

In the manufacturing of spiral-bevel and hypoid gears, circular cutter dimensions are usually based on the desired performance of a gear set. In large manufacturing operations, where several hundred gear geometries may have been cut over the years, the necessary cutter inventory may become quite large since the cutter diameters will differ from one geometry to another, which results in used storage space and associated costs in purchasing and maintaining the cutter parts. Interchangeability of cutters is therefore of significant interest to reduce cost while maintaining approved tooth geometries. An algorithm is presented which allows the use of a different cutter, either in diameter and/or pressure angle, to obtain the same tooth flank surface topography. A test case is presented to illustrate the usefulness of the method: the OB cutter diameter of an hypoid pinion is changed from 8.9500" to 9.1000". CMM results and the comparison of the bearing patterns before and after change show excellent correlation, and indicate that the new pinion can be used in place of the original pinion without performance or quality problems. Significant cost reductions may be obtained with the application of the method.

Comparison Experiment for Two Kinds of Hypoid Gear Drives

2010 ◽  
Vol 20-23 ◽  
pp. 1385-1390
Author(s):  
Hong Bin Yang ◽  
Xiao Hong Wang ◽  
Zong De Fang
Keyword(s):  
Working Conditions ◽  
Test Object ◽  
Hypoid Gear ◽  
Gear Drive ◽  
Comparison Experiment ◽  
Gear Drives

To develop a good quality of hypoid gear drive, the authors test the vibration and noise of two kinds of hypoid gear drives under different working conditions. The test object is a pair of hypoid gear drive used in the back axle of one minivan and a designed hypoid gear drive with high teeth based on the former. The results indicate that the hypoid gear drive with high teeth has lower vibration and noise.

A parameterized numerical method for generating discrete helical gear tooth surface allowing non-standard geometry

2008 ◽  
Vol 222 (6) ◽  
pp. 1033-1038 ◽  
Author(s):  
J Hedlund ◽  
A Lehtovaara
Keyword(s):  
Gear Tooth ◽  
Numerical Approach ◽  
Helical Gear ◽  
Tooth Surface ◽  
Tool Profile ◽  
Standard Geometry ◽  
Gear Manufacturing ◽  
Involute Gears ◽  
Gear Geometry ◽  
Tooth Flank

Gear analysis is typically performed using calculation based on gear standards. Standards provide a good basis in gear geometry calculation for involute gears, but these are unsatisfactory for handling geometry deviations such as tooth flank modifications. The efficient utilization of finite-element calculation also requires the geometry generation to be parameterized. A parameterized numerical approach was developed to create discrete helical gear geometry and contact line by simulating the gear manufacturing, i.e. the hobbing process. This method is based on coordinate transformations and a wide set of numerical calculation points and their synchronization, which permits deviations from common involute geometry. As an example, the model is applied to protuberance tool profile and grinding with tip relief. A fairly low number of calculation points are needed to create tooth flank profiles where error is <1 μm.

scholarly journals Minimization of Deviations of Gear Real Tooth Surfaces Determined by Coordinate Measurements

1993 ◽  
Vol 115 (4) ◽  
pp. 995-1001 ◽  
Author(s):  
F. L. Litvin ◽  
C. Kuan ◽  
J. C. Wang ◽  
R. F. Handschuh ◽  
J. Masseth ◽  
...  
Keyword(s):  
Linear Equations ◽  
Least Square Method ◽  
Least Square ◽  
Tooth Surface ◽  
Hypoid Gear ◽  
Overdetermined System ◽  
Entire Surface ◽  
First Order ◽  
Tooth Surfaces ◽  
Coordinate Measurements

The deviations of a gear’s real tooth surface from the theoretical surface are determined by coordinate measurements at the grid of the surface. A method has been developed to transform the deviations from Cartesian coordinates to those along the normal at the measurement locations. Equations are derived that relate the first order deviations with the adjustment to the manufacturing machine tool settings. The deviations of the entire surface are minimized. The minimization is achieved by application of the least-square method for an overdetermined system of linear equations. The proposed method is illustrated with a numerical example for hypoid gear and pinion.

Computerized Simulation of Transmission Errors and Shift of Bearing Contact for Hypoid Gear Drive With Conjugate Gear Tooth Surfaces

1994 ◽  
Author(s):  
Faydor L. Litvin ◽  
Jui-Sheng Chen ◽  
Thomas M. Sep ◽  
Jyh-Chiang Wang
Keyword(s):  
Gear Tooth ◽  
Low Noise ◽  
Linear Functions ◽  
Hypoid Gear ◽  
Transmission Errors ◽  
Gear Drive ◽  
Bearing Contact ◽  
Parabolic Function ◽  
Tooth Surfaces ◽  
Computerized Simulation

Abstract Computerized investigation of the influence of alignment errors on the transmission errors and the shift of the bearing contact is proposed. The investigation is performed for an imaginary hypoid gear drive with conjugate tooth surfaces. It is proven that the transmission functions caused by misalignment are periodic discontinues almost linear functions with the frequency of cycle of meshing. The above functions can be totally absorbed by a predesigned parabolic function. The shift of the bearing contact caused by misalignment has been determined as well. The performed investigation is based on computerized simulation of meshing and contact of gear tooth surfaces. The machine-tool settings for the generation of the designed gear drive have been determined. Numerical example that illustrates the developed theory is given. The performed investigation allows to determine the influence of gear misalignment on transmission errors, and design a low-noise hypoid gear drive by a properly predesigned parabolic function of transmission errors.

Computerized Design, Generation and Simulation of Meshing and Contact of Modified Flender Worm-Gear Drives

1996 ◽  
Author(s):  
I. H. Seol ◽  
Faydor L. Litvin
Keyword(s):  
Gear Tooth ◽  
Worm Gear ◽  
Numerical Examples ◽  
Transmission Errors ◽  
Gear Drive ◽  
Bearing Contact ◽  
Tooth Surfaces ◽  
Design Generation ◽  
Computerized Simulation ◽  
Gear Drives

Abstract The worm and worm-gear tooth surfaces of existing design of Flender gear drive are in line contact at every instant and the gear drive is very sensitive to misalignment. Errors of alignment cause the shift of the bearing contact and transmission errors. The authors propose : (1) Methods for computerized simulation of meshing and contact of misaligned worm-gear drives of existing design (2) Methods of modification of geometry of worm-gear drives that enable to localize and stabilize the bearing contact and reduce the sensitivity of drives to misalignment (3) Methods for computerized simulation of meshing and contact of worm-gear drives with modified geometry The proposed approach was applied as well for the involute (David Brown) and Klingelnberg type of worm-gear drives. Numerical examples that illustrate the developed theory are provided.

Tool Profile Modification of Hypoid Gear Machined by Duplex Helical Method

2021 ◽  
Author(s):  
Shunxing Wu ◽  
Hongzhi Yan ◽  
Zhiyong Wang ◽  
Rengui Bi ◽  
Jia Li
Keyword(s):  
Geometric Model ◽  
Tooth Surface ◽  
Gear Pair ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Edge Contact ◽  
Profile Modification ◽  
Tool Profile ◽  
Tooth Surfaces ◽  
Loaded Tooth Contact Analysis

Abstract For the hypoid gear pair of the heavy-duty vehicle drive axle machined by the duplex helical method, in order to avoid edge contact and stress concentration on the tooth surface, a four-segment tool profile is designed to modify the concave and convex surfaces simultaneously. First, the geometric model of the four-segment tool profile is established. Second, the mathematical model of the duplex helical method based on the four-segment tool profile is established, and the method of solving the tooth surface generated by the connecting points of the four-segment tool profile is given. Finally, the finite element method of loaded tooth contact analysis is used to analyze the meshing performance of the gear pair obtained by the four-segment tool profile modification, and the results are compared with the original gear pair. The results show that after the tooth surfaces are modified, the edge contact of the tooth surfaces are avoided, the stress distribution of the tooth surfaces are improved, the maximum contact stress of the tooth surfaces are reduced, and the fatigue and wear life of the tooth surface are improved.

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