Flank Correction for Spiral Bevel and Hypoid Gears on a Six-Axis CNC Hypoid Generator

Abstract

Because the contact bearings of spiral bevel and hypoid gears are highly sensitive to tooth flank geometry, it is desirable to reduce the flank deviations caused by machine errors and heat treatment deformation. Several methods already proposed for flank correction are based on the cutter parameters, machine settings, and kinematical flank motion parameters of a cradle-type universal generator, which are modulated according to the measured flank topographic deviations. However, because of the recently developed six-axis Cartesian-type computer numerical control (CNC) hypoid generator, both face-milling and face-hobbing cutting methods can be implemented on the same machine using a corresponding cutter head and NC code. Nevertheless, the machine settings and flank corrections of most commercial Cartesian-type machines are still translated from the virtual cradle-type universal hypoid generator. In contrast, this paper proposes a flank-correction methodology derived directly from the six-axis Cartesian-type CNC hypoid generator in which high-order correction is easily achieved through direct control of the CNC axis motion. The validity of this flank correction method is demonstrated using a numerical example of Oerlikon Spirac face-hobbing hypoid gears made by the proposed Cartesian-type CNC machine.

Advanced Design and Manufacture of Spiral Bevel Hypoid and Worm Gears

“…Because of the limited lebgth of this presentation, only small part of the corresponding publications can be referenced [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16].…”

Free-Form Flank Correction in Helical Gear Grinding Using a Five-Axis Computer Numerical Control Gear Profile Grinding Machine

“…A closed-loop manufacturing system is also provided to reduce grinding errors, especially in tooth thickness, profile, lead, and pitch. Nonetheless, to date, no correction method has been proposed for flank topography, even though many authors [1][2][3] have reported related research based on bevel gear cutting methods. The performance of these suggested correction methods, however, is restricted by a lack of free-form correction to wheel profiles (or cutting tool edges).…”

Ease-off based compensation of tooth surface deviations for spiral bevel and hypoid gears: Only the pinion needs corrections

“…They employed the multifunctional optimization system tool, based on the SQP method, to minimize a cost function defined as the maximum tooth surface deviation. Shih and Fong in [9] presented a method to identify the corrective settings of six-axis CNC hypoid generators (as opposed to the classic cradle-style generators) through application of linear regression. Artoni et al in [10] proposed a nonlinear least squares formulation for the problem of identifying the machine-tool settings needed to generate a target ease-off topography.…”