A Novel Method for Producing a Conical Skiving Tool With Error-Free Flank Faces for Internal Gear Manufacture

2018 ◽  
Vol 140 (4) ◽  
Author(s):  
Yi-Pei Shih ◽  
Yun-Jun Li
Keyword(s):  
Mathematical Model ◽  
Design Method ◽  
Gear Tooth ◽  
Tooth Surface ◽  
Tool Geometry ◽  
Surface Deviations ◽  
Tooth Surfaces ◽  
Novel Method ◽  
Profile Errors ◽  
Internal Gear

Power skiving for internal gears has drawn increased industry attention in recent years because it has higher precision and productivity than gear shaping or broaching. Yet even though the commonly adopted conical skiving tool has better wear resistance than the cylindrical one, when known design methods are used, the tool geometry is still subject to profile errors. This paper therefore proposes a novel design method for the conical skiving tool and establishes a mathematical model of error-free flank faces. These faces are formed by conjugating the cutting edges on the rake faces—derived from a group of generating gears with progressively decreasing profile-shifted coefficients—with the work gear. A mathematical model of the work gear tooth surfaces produced by the cutting edges (over flank faces) of tool at different resharpened depths is then adopted to examine the tooth surface deviations produced with their theoretical equivalents. The results verify the correctness of the mathematical models.

An Ease-Off Based Method for Loaded Tooth Contact Analysis of Hypoid Gears Having Local and Global Surface Deviations

2010 ◽  
Vol 132 (7) ◽  
Author(s):  
M. Kolivand ◽  
A. Kahraman
Keyword(s):  
Gear Tooth ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Hypoid Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Hypoid Gears ◽  
Surface Deviations ◽  
Tooth Surfaces ◽  
Loaded Tooth Contact Analysis

Actual hypoid gear tooth surfaces do deviate from the theoretical ones either globally due to manufacturing errors or locally due to reasons such as tooth surface wear. A practical methodology based on ease-off topography is proposed here for loaded tooth contact analysis of hypoid gears having both local and global deviations. This methodology defines the theoretical pinion and gear tooth surfaces from the machine settings and cutter parameters, and constructs the surfaces of the theoretical ease-off and roll angle to compute for the unloaded contact analysis. This theoretical ease-off topography is modified based on tooth surface deviations and is used to perform a loaded tooth contact analysis according to a semi-analytical method proposed earlier. At the end, two examples, a face-milled hypoid gear set having local deviations and a face-hobbed one having global deviations, are analyzed to demonstrate the effectiveness of the proposed methodology in quantifying the effect of such deviations on the load distribution and the loaded motion transmission error.

A parametric analysis of the surface roughness of teeth shaped by a pinion shaper cutter and guidelines for choosing process parameters

2019 ◽  
Vol 233 (21-22) ◽  
pp. 7368-7377
Author(s):  
Mattias Svahn
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Parametric Analysis ◽  
Gear Tooth ◽  
Cutting Parameters ◽  
Three Dimensions ◽  
Tooth Surface ◽  
Roughness Parameters ◽  
Helical Gears ◽  
Novel Method

A parametric mathematical model is presented, by which it is possible to determine the machined gear tooth surface topography cut by a pinion shaper cutter. Arbitrary internal or external helical gears designs can be considered, the gear and the shaper cutter must only share a basic rack design. The basic rack has here an elliptical fillet, as it allows fewer tool tooth numbers without the risk of undercut. The machined tooth surface is presented in three dimensions and by surface roughness parameters [Formula: see text], and [Formula: see text]. A novel method to choose cutting parameters and tool design is also presented.

Estimation of Gear Friction Coefficient using Directional Parameter of Tooth Surface

2021 ◽  
pp. 1-27
Author(s):  
Junichi Hongu ◽  
Ryohei Horita ◽  
Takao Koide
Keyword(s):  
Friction Coefficient ◽  
Contact Surface ◽  
Gear Tooth ◽  
Correction Term ◽  
Tooth Surface ◽  
Oil Film ◽  
Tooth Surfaces ◽  
Frictional Coefficients ◽  
Finishing Processes ◽  
The Relationship

Abstract This study proposes a modification of the Matsumoto equation using a directional parameter of tooth surfaces to adapt various gear finishing processes. The directional parameters of a contact surface, which affect oil film formations, have been discussed in the field of tribology; but this effect has been undetermined on the meshing gear tooth surfaces having directional machining marks. Thus, this paper investigates the relationship between the gear frictional coefficients and the directional parameters (based on ISO25178) of their tooth surfaces with the various finishing processes; and modifies the Matsumoto equation by introducing a new directional parameter to augment the various gear finishing processes. Our findings indicate that through optimizing the coefficient of the correction term the include the new directional parameter, the calculated friction values using the modified Matsumoto equation correlate more highly to the experimental friction values than that using the unmodified Matsumoto equation.

Simulation Analysis of Contact Pattern and Strength of WN Gears Having Tooth Surface Deviations

2012 ◽  
Vol 479-481 ◽  
pp. 944-948 ◽  
Author(s):  
Dian Hua Chen ◽  
Zhong Wei Zhang
Keyword(s):  
Simulation Analysis ◽  
Practical Method ◽  
Transmission Error ◽  
Tooth Surface ◽  
Contact Pattern ◽  
The Finite Element Method ◽  
Tooth Contact Analysis ◽  
Surface Deviations ◽  
Tooth Surfaces ◽  
Loaded Tooth Contact Analysis

A practical method based on normal gaps topography is proposed here for loaded tooth contact analysis of WN gear having tooth surface deviations. The simulation of meshing state and tooth strength of WN gear are provided with real tooth surfaces. In the study normal gaps distribution is adopted to calculate tooth surface contact elastic deformation and local deviations due to manufacturing errors and tooth surface wear. For WN gear, the loaded distribution on the contact zone in meshing tooth surface has not been investigated because of their complexity in the contact state. The finite element method is adopted to analyze the contact pattern and tooth strength. The study has concretely calculated the contact pressure and zone of meshing in different loaded and transmission error. At the end examples are analyzed to demonstrate the effectiveness of the proposed method in quantifying effect of such deviations on the loaded distribution and tooth stress distribution.

Tooth Undercutting of Beveloid Gears

2000 ◽  
Author(s):  
Chia-Chang Liu ◽  
Chung-Biau Tsay
Keyword(s):  
Gear Tooth ◽  
Singular Points ◽  
Tooth Surface ◽  
Involute Gear ◽  
Beveloid Gears ◽  
Tooth Surfaces

Abstract A beveloid gear can be viewed as an involute gear of which the profile-shifted coefficient linearly decreases from the heel to the toe. Therefore, tooth undercutting occurs and singular points appear on the tooth surfaces near the toe. When undercutting occurs, the gear tooth is comparatively weak. In this study, the conditions of tooth undercutting of beveloid gears were derived and specific phenomena were also investigated by numerical illustrated examples. In addition, according to the characteristics of tooth undercutting on the beveloid gear tooth surface, a novel type hob cutter with varying cutting depths was designed to avoid tooth undercutting of the beveloid gear.

Mathematical Model and Surface Deviation of Helipoid Gears Cut by Shaper Cutters

2003 ◽  
Vol 125 (2) ◽  
pp. 351-355 ◽  
Author(s):  
Jun-Long Wu ◽  
Chia-Chang Liu ◽  
Chung-Biau Tsay ◽  
Shigeyoshi Nagata
Keyword(s):  
Mathematical Model ◽  
Power Transmission ◽  
Tooth Surface ◽  
Cutting Mechanism ◽  
Hypoid Gears ◽  
Helical Gears ◽  
Number Of Teeth ◽  
Surface Deviations ◽  
Surface Deviation

Crossed-axis helical gears and hypoid gears are two conventional crossed-axis power transmission devices. Helipoid gears, a novel gear proposed herein, possess the merits of the crossed-axis helical and hypoid gears. A mathematical model of the proposed helipoid gear cut by shapers is also derived according to the cutting mechanism and the theory of gearing. The investigation shows that the tooth surface varies with the number of teeth of the shaper. Computer graphs of the helipoid gear are presented according to the developed gear mathematical model, and the tooth surface deviations due to the number of teeth of the shaper are also investigated.

The Undercutting of Circular-Cut Spiral Bevel Gears

1992 ◽  
Vol 114 (2) ◽  
pp. 317-325 ◽  
Author(s):  
Zhang-Hua Fong ◽  
Chung-Biau Tsay
Keyword(s):  
Gear Tooth ◽  
Sufficient Conditions ◽  
Bevel Gear ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Sufficient And Necessary Conditions ◽  
Spiral Bevel

Undercutting is a serious problem in designing spiral bevel gears with small numbers of teeth. Conditions of undercutting for spiral bevel gears vary with the manufacturing methods. Based on the theory of gearing [1], the tooth geometry of the Gleason type circular-cut spiral bevel gear is mathematically modeled. The sufficient and necessary conditions for the existence and regularity of the generated gear tooth surfaces are investigated. The conditions of undercutting for a circular-cut spiral bevel gear are defined by the sufficient conditions of the regular gear tooth surface. The derived undercutting equations can be applicable for checking the undercutting conditions of spiral bevel gears manufactured by the Gleason Duplex Method, Helical Duplex Method, Fixed Setting Method, and Modified Roll Method. An example is included to illustrate the application of the proposed undercut checking equations.

Correlation of Tooth Surface Wear Prediction With Experimental Results of Spur and Helical Gears in Commercial Vehicle Transmissions

2013 ◽  
Author(s):  
Carlos H. Wink
Keyword(s):  
Commercial Vehicle ◽  
Gear Tooth ◽  
Numerical Procedure ◽  
Tooth Wear ◽  
Experimental Results ◽  
Analytical Models ◽  
Tooth Surface ◽  
Wear Prediction ◽  
Vehicle Transmissions ◽  
Tooth Surfaces

Gear pair dynamic loads can increase significantly with involute profile changes caused by wear resulting in vibration and noise issues. Tooth stresses such as root stress and contact stress can also increase reducing gear life. Wear prediction is important during the design phase to minimize the effects of worn tooth surfaces on product performance. Some analytical models have been proposed to predict gear tooth wear; however published correlations of predictions with experimental results are still limited, especially from the gear industry. But they are vital to build confidence in analytical tools. This paper presents a correlation of wear predictions with experimental results of spur and helical gear pairs that are used in commercial vehicle transmissions. Four different gear lubricants were considered, and also three tooth finishes, grinding, honing, and shaving. A modified Archard’s wear model was used for wear predictions. The model combines a gear contact model and an iterative numerical procedure to account for tooth surface changes. Wear coefficients were determined from experiments. The correlation between predictions and dynamometer testing data was established.

Study on Design Method of the Double Arc Gear Hobs

2013 ◽  
Vol 823 ◽  
pp. 257-260
Author(s):  
Jie Wu ◽  
Jia Quan Wang
Keyword(s):  
Design Method ◽  
Gear Tooth ◽  
Tooth Profile ◽  
Tooth Surface ◽  
Engineering Practice ◽  
Approximate Design ◽  
Circular Arc ◽  
Running Performance ◽  
Engagement Theory ◽  
Gear Rack

This article find that one of the effecting the double circular arc gear s running performance is the double circular arc gear tooth profile precision, through analysis to the running-in properties of double arc gear. The problems about tooth profile precision of gear hobs caused by the current profiling theory and approximate design method of gear hobs are analyzed. In the design of circular arc gear hob, use the space engagement theory, can eliminating the tooth error. Acquiring the equation of hobs basic of worm tooth surface by analytical and calculation that the establishment of basic gear rack and worm of hob meshing. The hob not only eliminate the tooth profile error in manufacturing, but also improve the running performance of double circular arc gear, and provides the theory evidence for engineering practice.

The Deformation Analysis on Tooth Profiles with Electroplated CBN Hard Gear-Honing-Tools

2012 ◽  
Vol 426 ◽  
pp. 159-162 ◽  
Author(s):  
Man Dong Zhang ◽  
H.H. Zhao ◽  
Ming Lv
Keyword(s):  
Gear Tooth ◽  
Tooth Profile ◽  
Tooth Surface ◽  
Deformation Analysis ◽  
Normal Deformation ◽  
Gear Honing ◽  
Important Means ◽  
Profile Errors ◽  
Tooth Profile Errors ◽  
Exact Analytical Method

Using electroplating CBN hard gear-honing-tools with standard involute, the vicinity of the workpiece tooth pitch circle will be a “mid concave” error, the root of the tooth will be a “dig root” error generally. For the formation factors of the error are more complex, it is difficult to calculate errors with an exact analytical method. To this end, by using Pro/E and ANSYS software, the contact analysis of electroplating CBN hard honing process was simulated. The honed tooth surface normal deformation analysis was the important means to determine extent of tooth profile error, through the normal deformation analysis based on simulation results, the location and extent of normal deformation was determined. Practice shows that the location and extent of the normal deformation has been a certain relationship with processing gear tooth profile errors. It is provided a theoretical basis to make the gear-honing tooth surface modification as possible.

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