Machining and Running Test of High-Performance Face Gear Set

2011 ◽  
Author(s):  
Isamu Tsuji ◽  
Hiroshi Gunbara ◽  
Kazumasa Kawasaki ◽  
Akiyasu Takami
Keyword(s):  
High Performance ◽  
Design Method ◽  
Maximum Load ◽  
Transmission Efficiency ◽  
Alignment Error ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Load Torque ◽  
Tooth Contact ◽  
The Face

The purpose of this research is to develop a high-performance face gear set for aircraft. The geometrical design method of the face gear has already been proposed, and how to decide an effective engagement area under the design parameter has been clarified. A numerical example is presented based on the proposed method. Before machining test, the modified-tooth was decided by the developed Tooth Contact Analysis (TCA) program in order to control the tooth contact pattern. The influence of alignment error of each axis of gear was investigated using TCA. The designed modified-tooth was processed by the Multi-Tasking machine. Finally, running test was performed at a pinion rotating speed of 970 rpm. The face gear set can be operated continuously at an maximum load torque 1390 N · m, without any trouble. The transmission efficiency reached 98.9% under maximum load torque. This cutting method of the face gear introduces a new degree of freedom for defining optional shapes of tooth modification.

Computer Simulation Analysis of Bending Stress for Face Gear with a New Type Fillet Tooth Surface

2011 ◽  
Vol 86 ◽  
pp. 411-414
Author(s):  
Yun Bo Shen ◽  
Jie Gao ◽  
Wen Qiang Ding
Keyword(s):  
Computer Simulation ◽  
Surface Structure ◽  
Spur Gear ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Bending Stress ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
The Face

Bending stress is a principal factor that defines the fatigue life of face gear. A new tooth surface structure with circular arc of fillet surface for the face gear has been developed. A method of processing or cutting of fillet surfaces of helical face gear by application of a shaper with tooth rounded top has also been represented. The bending stress of the tooth of face gear with new surface structure has been performed by computer simulation. Two versions of finite element model of tooth surfaces of face gear are generated by application of numerical technology. One version is based on the cutting shaper with tooth top shaper corner and another version is with addendum rounded top. Tooth contact analysis (TCA) and loaded tooth contact analysis (LTCA) for the two versions of face gear drives with helical spur gear are also considered. The results of simulation show that the bending stress of tooth surface of the face gear with fillet surface generated by the rounded top of the shaper is 12% lower than the first version’s.

Tooth Contact Analysis of Face Gear Drive Modified by a Grinding Worm

2010 ◽  
Vol 139-141 ◽  
pp. 1154-1157 ◽  
Author(s):  
Hui Guo ◽  
Ning Zhao ◽  
Hao Gao
Keyword(s):  
Gear Tooth ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Alignment Error ◽  
Contact Ratio ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Gear Drive ◽  
Bearing Contact

This paper proposes a modification method for tooth surface of face gear drive with a grinding worm on a numerical grinding machine. The surface equation of grinding worm is derived, and the coordinate System of generating the worm is established. Tooth contact analysis (TCA) is performed to investigate the performance of face gear drive before and after modification, and the alignment error is considered. This method can obtain a more stable bearing contact in contrast to the method by increasing tooth number of shaper. The longitudinal bearing contact on the face-gear tooth surface has been obtained which will increase the contact ratio. By modification the edge contact at surface edges of the gears can be avoided and the modification magnitude can be controlled freely.

scholarly journals Lubricated Loaded Tooth Contact Analysis and Non-Newtonian Thermoelastohydrodynamics of High-Performance Spur Gear Transmission Systems

Lubricants ◽  
2020 ◽  
Vol 8 (2) ◽  
pp. 20 ◽  
Author(s):  
Gajarajan Sivayogan ◽  
Ramin Rahmani ◽  
Homer Rahnejat
Keyword(s):  
High Speed ◽  
High Performance ◽  
Spur Gear ◽  
Contact Analysis ◽  
Operating Conditions ◽  
Tooth Contact Analysis ◽  
Transmission Systems ◽  
Tooth Contact ◽  
Contact Kinematics ◽  
Loaded Tooth Contact Analysis

Energy efficiency and functional reliability are the two key requirements in the design of high-performance transmissions. Therefore, a representative analysis replicating real operating conditions is essential. This paper presents the thermoelastohydrodynamic lubrication (TEHL) of meshing spur gear teeth of high-performance racing transmission systems, where high generated contact pressures and lubricant shear lead to non-Newtonian traction. The determination of the input contact geometry of meshing pairs as well as contact kinematics are essential steps for representative TEHL. These are incorporated in the current analysis through the use of Lubricated Loaded Tooth Contact Analysis (LLTCA), which is far more realistic than the traditional Tooth Contact Analysis (TCA). In addition, the effects of lubricant and flash surface temperature rise of contacting pairs, leading to the thermal thinning of lubricant, are taken into account using a thermal network model. Furthermore, high-speed contact kinematics lead to shear thinning of the lubricant and reduce the film thickness under non-Newtonian traction. This comprehensive approach based on established TEHL analysis, particularly including the effect of LLTCA on the TEHL of spur gears, has not hitherto been reported in literature.

Compound transmission principle analysis of eccentric curve-face gear pair with curvilinear-shaped teeth based on tooth contact analysis

2021 ◽  
pp. 095440622110470
Author(s):  
Chao Lin ◽  
Yu Wang ◽  
Yanan Hu ◽  
Yongquan Yu
Keyword(s):  
Axial Direction ◽  
Contact Analysis ◽  
Gear Pair ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Contact Points ◽  
Tooth Surfaces ◽  
Set Up ◽  
Curve Face

A new type of compound transmission gear pair was put forward, called eccentric curve-face gear pair with curvilinear-shaped teeth. It could realize reciprocating motion of the gear shaft when the intersecting shafts achieve transferring motion and power through its unique tooth profile. The compound transmission principle of this gear pair was fully established based on the profile-closure process of axial direction and meshing process of the end face. The tooth surfaces of the eccentric curve-face gear and non-circular gear were generated. The contact paths of different teeth were obtained, and the compound transmission principle of eccentric curve-face gear pair with curvilinear-shaped teeth was verified by tooth contact analysis. By analyzing the mechanical characteristics of time-varying contact points, the changing rule of contact force was studied, and the compound transmission principle of the gear pair was further revealed from mechanics. Moreover, the experimental platform for transmission of eccentric curve-face gear pair with curvilinear-shaped teeth was set up to measure the motion law and contact area, and the correctness of the analysis results was verified.

A New Method of Motion Rule Synthesis for Face Gear Manufacturing by Plane-Cutter

2017 ◽  
Vol 140 (2) ◽  
Author(s):  
Xian-long Peng ◽  
Qin-yu Niu ◽  
Wei Guo ◽  
Zong-de Fang
Keyword(s):  
Equivalence Principle ◽  
Numerical Control ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Transmission Errors ◽  
The Face ◽  
Gear Manufacturing ◽  
Motion Parameters ◽  
Involute Surface ◽  
Gear Machine

The application of a Gleason Coniflex cutter (plane-cutter) to a modern Phoenix bevel gear machine tool in face gear manufacturing has an advantage of involving a universal cutter or grinder and an available existing machine. It is valuable to research this method for face gear manufacturing. First, the principle of the application of the plane-cutter in face gear manufacturing is presented. Then, the geometry of the cutter is defined, and the model of the face gear generated by this method in abstract is established. Third, a method that uses a predesigned contact path for the synthesis with the motion parameters of the plane-cutter is proposed; controllable transmission errors are considered in this process. Fourth, based on the equivalence principle of the position and direction, the computer numerical control (CNC) motion rules of all spindles of the machine are determined, and the surface generated by the machine is presented. Finally, numerical simulation of an example demonstrates that although the surface generated by the plane-cutter, to a certain extent, deviates from the theoretical surface generated by the traditional method, the surface, in meshing with the standard involute surface of the pinion, presents a good geometric meshing performance based on tooth contact analysis (TCA), except for a shortened contact ellipse.

Research on Meshing Characteristics for Face Gear with Arcuate Tooth

2011 ◽  
Vol 86 ◽  
pp. 39-42
Author(s):  
Xiang Wei Cai ◽  
Zong De Fang ◽  
Jin Zhan Su
Keyword(s):  
Contact Analysis ◽  
Tooth Surface ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Surface Equation ◽  
Transmission Errors ◽  
Gear Drive ◽  
Parabolic Function ◽  
The Face ◽  
Meshing Characteristics

The generating of face gear with arcuate tooth has been proposed in this paper, and the meshing characteristics are investigated. Based on the concept of imaginary gear cutter, tooth surface equation has been derived, flank modification has also been considered. The transmission errors and bearing contacts of the face gear drive with arcuate tooth under different assembly conditions are investigated by applying the tooth contact analysis. The numerical results reveal that the bearing contacts are not sensitive to the errors of misalignments, and a more favorable type parabolic function of transmission errors with better symmetry and reduced amplitude may be obtained according to the modification of the face gear.

Research on Meshing of Face Gear Drive under Errors of Alignment and Machining

2010 ◽  
Vol 44-47 ◽  
pp. 1948-1951
Author(s):  
Ning Zhao ◽  
Hui Guo
Keyword(s):  
Helix Angle ◽  
Transmission Error ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Gear Drive ◽  
Machining Errors ◽  
Alignment Errors

The coordinate systems for cutting face gears and for meshing of face gear drive with involute cylindrical pinion. The tooth surface equation of face gear with machining errors is deviated, such as change of shaft angle, change of shortest distance between face gear and cutter tool axes, helix angle of cutter tool. Tooth contact analysis applied in the paper considered with the alignment error of the driving system. The tooth contact path and the transmission error of the face gear drive were simulated through the tooth contact analysis for different alignment errors and machining errors. The simulation results indicate that all of the alignment errors and machining error don’t cause transmission error except helix angle error of the cutting tool. The errors will bring the shift of the contact path on gear teeth. The shift of bearing contact can be reduced by combination of different errors of alignment or machining.

Loaded Tooth Contact Analysis of Face Gear Drive with Modification

2010 ◽  
Vol 29-32 ◽  
pp. 1711-1716
Author(s):  
Shu Yan Zhang ◽  
Hui Guo
Keyword(s):  
Transmission Error ◽  
Contact Analysis ◽  
Tooth Surface ◽  
Face Gear ◽  
Tooth Contact Analysis ◽  
Tooth Contact ◽  
Gear Drive ◽  
Bearing Contact ◽  
Tooth Number ◽  
Loaded Tooth Contact Analysis

A double direction modification with a grinding worm is applied on tooth surface of face gear drive. The surface equations of the rack cutter, shaper and grinding worm are derived respectively. Loaded tooth contact analysis (LTCA) with finite element method (FEM) is performed to investigate the meshing performance of face gear drive before modification and after modification. The modification by a grinding worm can obviously reduce the sensitivity of face gear drive to misalignment; the bending stress and the contact stress are reduced with avoiding edge contact; the load transmission error is reduced. This method can obtain a more stable bearing contact in contrast to the method by increasing tooth number of shaper, and the modification magnitude can be controlled freely. The investigation is illustrated with numerical examples.

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