Robust Optimization of the Loaded Contact Pattern in Hypoid Gears With Uncertain Misalignments

Abstract

This paper presents an automatic procedure to optimize the loaded tooth contact pattern of face-milled hypoid gears with misalignments varying within prescribed ranges. A two-step approach is proposed to solve the problem: in the first step, the pinion tooth microtopography is automatically modified to bring the perturbed contact patterns (as the assembly errors are varied within the tolerance limits) match a target area of the tooth while keeping them off the edges; in the second step, a subset of the machine-tool settings is identified to obtain the required topography modifications. Both steps are formulated and solved as unconstrained nonlinear optimization problems. While the general methodology is similar to the one recently proposed by the same authors for the optimization at nominal conditions, here, the robustness issues with respect to misalignment variations are considered and directly included in the optimization procedure: no a posteriori check for robustness is therefore required. Numerical tests show that nominally satisfactory and globally robust hypoid pairs can be designed by a direct process and within a unified framework, thus avoiding tiresome trial-and-error loops

Tooth flank reconstruction and optimizations after simulation process modeling for the spiral bevel gear

“…It has been mentioned by Artoni et al 22 and Gabicci et al 23 Recently, Lin and Fong 24 have conducted a detailed study. As shown in Figure 11(a), it is the residual normal error of the B-spline fitting with 37 Â 33 control points.…”

A new methodology to optimize spiral bevel gear topography

“…Gabiccini [17] uses Artoni's work [13]. His aim is the reduction of the sensitivity of the loaded contact path in order to bear the relative displacements of the gear axes.…”

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

“…Gabiccini et al [32] presented an automated procedure to optimize the loaded tooth contact pattern of face-milled hypoid gears with misalignments varying within their prescribed ranges. An algorithmic framework was proposed by Artoni et al [33] to accurately solve the problem of multi-objective ease-off optimization for spiral bevel and hypoid gears.…”

“…[27][28][29][30][31][32][33][34][35][36][37][38][39]. Procedure to obtain the correction values of machine settings for tooth surface modification in the case of face hobbing and the construction of the corresponding prototype gear cutting machine is presented in Ref.…”