Manufacture of Optimized Face-Hobbed Spiral Bevel Gears on Computer Numerical Control Hypoid Generator

Abstract

In this study, a method is proposed for the advanced manufacture of face-hobbed spiral bevel gears on CNC hypoid generators with optimized tooth surface geometry. An optimization methodology is applied to systematically define optimal head-cutter geometry and machine tooi settings to introduce optimal tooth modifications. The goal of the optimization is to simultaneously minimize tooth contact pressures and angular dispiacement error of the driven gear (the transmission error). The optimization is based on machine toot setting variation on the cradle-type generator conducted by optimai polynomial functions. An algorithm is developed for the execution of motions on the CNC hypoid generator using the relations on the cradle-type machine. Effectiveness of the method was demonstrated by using a face-hobbed spiral bevei gear exampie. Significant reductions in the maximum tooth contact pressure and in the transmission errors were obtained.

A motion control method for face hobbing on CNC hypoid generator

“…A. Artoni et al developed a method for accurate grinding of face-hobbing bevel gear [11]. Simon optimized head-cutter geometry and machine tool settings to introduce optimal tooth modifications, adopted nonlinear correction motions in reducing transmission error amplitudes, and contact pressure of a hypoid gear pair on CNC hypoid generator [12][13][14]. Shih and Fong proposes a flank-correction methodology derived directly from the six-axis Cartesiantype CNC hypoid generator [15].…”

“…With respect to control method of CNC hypoid generator, Simon and Shih derived the relative position and attitude between cutter and workpiece, using cradle type and Cartesian-type hypoid generators; solving nonlinear equations to obtain each axis coordinate of CNC hypoid generator [14,15]. Shih also studied the machining method of face-hobbing straight bevel gears using six-axis CNC bevel gear generator.…”

An integration method of design and machining for spiral bevel gears based on universal CNC machine tools

“…on special CNC milling machine tools has been a closedloop manufacturing process including digital design and calculation [3][4][5][6][7][8], CNC machining [9][10][11][12], digital inspection and correction [13][14][15][16]. Nevertheless, due to the restrictions of processing principle for spiral bevel gears, there are many obvious defects (e.g., large tool size, low processing efficiency, and high production cost) when the large-sized spiral bevel gears are machined on special machine tools by traditional methods (face-milling or face-hobbing).…”

Theoretical and Experimental Study on Contact Characteristics of Spiral Bevel Gears under Quasi-Static and Large Loading Conditions

“…Currently, the new optimization method based on the loaded tooth contact analysis (LTCA) for improving strength and contact performance of bevel gears has been a great concern to scholars worldwide. Simon analyzed the influences of machine settings and misalignments on tooth contact pressure and loaded transmission error, and then presented a method to improve gear meshing performance by reducing the loaded transmission error and the maximum tooth contact pressure of hypoid gears [6][7][8][9][10]. Antoni et al studied the ease-off optimizing method for loaded transmission error and contact surface of bevel gears, which reduced the risk of vibration and noise [11][12][13].…”