Advertisement

Optimal machine tool settings for face-hobbed hypoid gears manufactured on CNC hypoid generator

  • Vilmos V. SimonEmail author
ORIGINAL ARTICLE

Abstract

In this study, a method is proposed for the determination of optimal machine tool setting for the manufacture of face-hobbed hypoid gears on CNC hypoid generators. The optimal head-cutter geometry and machine tool settings are determined to introduce the optimal tooth modifications into the teeth of face-hobbed hypoid gears. The goals of the tooth surface modifications are to reduce the tooth contact pressure and the transmission errors and to decrease the sensitivity of the gear pair to errors in tooth surfaces and to the relative positions of the mating members. An optimization methodology is applied to systematically define the optimal head-cutter geometry and machine tool settings to simultaneously minimize tooth contact pressures and angular displacement error of the driven gear. The method is based on the machine tool setting variation on the cradle-type generator conducted by polynomial functions of fifth order. An algorithm is developed for the execution of motions on the CNC hypoid generator using the optimal relations on the cradle-type machine. Effectiveness of the method was demonstrated by using a face-hobbed hypoid gear example. Significant reductions in the maximum tooth contact pressure and in the transmission errors were obtained.

Keywords

Face-hobbed Hypoid gear Tooth surface modification Optimization Manufacture CNC generator 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Cao X, Fang Z, Xu H, Su J (2008) Design of pinion machine tool-settings for spiral bevel gears by controlling contact path and transmission errors. Chinese J Aeronautics 21:179–186CrossRefGoogle Scholar
  2. 2.
    Shih YP (2010) A novel ease-off flank modification methodology for spiral bevel and hypoid gears”. Mech Mach Theory 45:1108–1124CrossRefzbMATHGoogle Scholar
  3. 3.
    Artoni A, Kolivand M, Kahraman A (2010) “An Ease-off Based Optimization of the Loaded Transmission Error of Hypoid Gears”, ASME J. Mech Des 132:011010Google Scholar
  4. 4.
    Gonzalez-Perez I, Fuentes A, Hayasaka K (2010) Analytical determination of basic machine-tool settings for generation of Spiral Bevel Gears from Blank Data. ASME J Mech Des 132:1–11, Art. No. 101002CrossRefGoogle Scholar
  5. 5.
    Artoni A, Gabiccini M, Kolivand M (2013) Ease-off based compensation of tooth surface deviations for Spiral Bevel and hypoid gears: only the pinion needs corrections. Mech Mach Theory 61:84–101CrossRefGoogle Scholar
  6. 6.
    Xie S (2013) A genuine face milling cutter model for Spiral Bevel and hypoid gears. Int J Advanced Man Tech 67:2619–2626CrossRefGoogle Scholar
  7. 7.
    Takeda R, Komori M, Tatsuya N, Kimura Y, Takayuki N, Okuda K, Yamamoto S (2014) Performance analysis of generated hypoid gear based on measured tooth flank form data. Mech Mach Theory 72:1–16CrossRefGoogle Scholar
  8. 8.
    Perez IG, Fuentes A, Orzaez RR (2015) An approach for determination of basic machine-tool settings from blank data in face-hobbed and face-milled hypoid gears. ASME J Mech Des 137:1–10, Art. No. 093303Google Scholar
  9. 9.
    Tan R, Chen B, Peng C (2015) General mathematical model of spiral bevel gears of pure-rolling contact. Proc Inst Mech Eng Part C – J Mech Eng Sc 229(15):2810–2826CrossRefGoogle Scholar
  10. 10.
    Gao Y, Chen B, Liang D (2015) Mathematical models of hobs for conjugate-curve gears having three contact points. Proc Inst Mech Eng Part C – J Mech Eng Sc 229(13):2402–2011CrossRefGoogle Scholar
  11. 11.
    Mo S, Zhang Y (2015) Spiral bevel gear true tooth surface precise modeling and experiments studies based on machining adjustment parameters. Proc Inst Mech Eng Part C – J Mech Eng Sc 229(14):2524–2533CrossRefGoogle Scholar
  12. 12.
    Li L, Yang Z, Wang Y, Zhang X (2011) Cutting geometry and base-cone parameters of manufacturing hypoid gears by generating-line method. Mech Eng J 5:19–25CrossRefGoogle Scholar
  13. 13.
    Zhang Y, Yan HZ, Zeng T (2015) Computerized design and simulation of meshing and contact of formate hypoid gears generated with a duplex helical method. Str Vest J Mech Eng 61:523–532CrossRefGoogle Scholar
  14. 14.
    Yang HB, Yao RD (2015) Methods and approaches for the modeling of spiral bevel gear. Proc 2015 Int Conf Int Sys Res Mechatr Eng Book Series Adv Int Sys Res 121:1670–1676Google Scholar
  15. 15.
    Lin CH, Fong ZH (2015) Numerical tooth contact analysis of a bevel gear set by using measured tooth geometry data. Mech Mach Theory 84:1–24CrossRefGoogle Scholar
  16. 16.
    Goldrich RN (1989) Theory of Six Axes CNC Generation of Spiral Bevel and Hypoid Gears, AGMA Fall Tech. Meeting, Pittsburgh, Paper No. 89FTM9Google Scholar
  17. 17.
    Chang SL, Tsay CB, Nagata S (1997) A general mathematical model for gears by CNC hobbing machines. ASME J Mech Des 119:108–113CrossRefGoogle Scholar
  18. 18.
    Thomas J, Vogel O (2005) 6M machine kinematics for bevel and hypoid gears. VDI Ber 1904(1):435–451MathSciNetGoogle Scholar
  19. 19.
    Liu H, Liu Q, Zhao D, Song D, Wang J (2007) The Realization of the “SFT” and “HFT” Method on the CNC Hypoid Cutting Machine. Proc 10th ASME Int Power Trans Gearing Conf, Las Vegas Paper No. DETC2007/PTG-34872:1–6Google Scholar
  20. 20.
    Shih YP, Fong ZH (2008) Flank correction for spiral bevel and hypoid gears on a six-axis CNC hypoid generator. ASME J Mech Des 130:062604CrossRefGoogle Scholar
  21. 21.
    Fan Q (2010) Tooth surface error correction for face-hobbed hypoid gears. ASME J Mech Des 132:1–8, Art. No. 011004CrossRefGoogle Scholar
  22. 22.
    Kawasaki K (2010) Manufacturing method for large-sized bevel gears in cylo-palloid system using multi-axis control and multi-tasking machine tool. Int Conf Gears Munich VDI-Berichte 2108(1):337–348Google Scholar
  23. 23.
    Simon V (2010) Advanced manufacture of spiral bevel gears on cnc hypoid generating machine. ASME J Mech Des 132:006004-1-8CrossRefGoogle Scholar
  24. 24.
    Simon V (2011) Generation of hypoid gears on CNC hypoid generator. ASME J Mech Des 133:121007-1-9CrossRefGoogle Scholar
  25. 25.
    Zhou K, Tang J (2011) Envelope-approximation theory of manufacture technology for point-contact tooth surface on six-axis CNC hypoid generator. Mech Mach Theory 46:806–819CrossRefzbMATHGoogle Scholar
  26. 26.
    Gabiccini M, Bracci A, Battaglia E (2011) On the estimation of continuous mappings from cradle-style to 6-axis machines for face-milled hypoid gear generation. Mech Mach Theory 46:1492–1506CrossRefzbMATHGoogle Scholar
  27. 27.
    Alves JT, Guingand M, de Vaujany JP (2013) Designing and manufacturing spiral bevel gears using 5-axis computer numerical control (CNC) milling machines. ASME J Mech Des 135:024502CrossRefGoogle Scholar
  28. 28.
    Chen SH, Fong ZH (2015) Study on the cutting time of the hypoid gear tooth flank. Mech Mach Theory 84:113–124CrossRefGoogle Scholar
  29. 29.
    Chen ZC, Wasif M (2015) A generic and theoretical approach to programming and post-processing for hypoid gear machining on multi-axis CNC face-milling machines. Int J Adv Man Tech 81:135–148CrossRefGoogle Scholar
  30. 30.
    Zhang W, Cheng B, Guo X, Zhang M, Xing Y (2015) A motion control method for face hobbing on CNC hypoid generator”. Mech Mach Theory 92:127–143CrossRefGoogle Scholar
  31. 31.
    Kawasaki K, Isamu T, Gunbara H, Houjoh H (2015) Method for remanufacturing large-sized skew bevel gears using cnc machining center”. Mech Mach Theory 92:213–229CrossRefGoogle Scholar
  32. 32.
    Simon V (2011) Influence of tooth modifications on tooth contact in face-hobbed spiral bevel gears. Mech Mach Theory 46:1980–1998CrossRefGoogle Scholar
  33. 33.
    Simon V (2014) Optimization of face-hobbed hypoid gears. Mech Mach Theory 77:164–181CrossRefGoogle Scholar
  34. 34.
    Kubo A (1981) Estimation of Gear Performance. Int Symp Gearing and Power Trans, Tokyo, II, pp. 201–206Google Scholar
  35. 35.
    Simon V (2000) Load distribution in hypoid gears. ASME J Mech Des 122:529–535CrossRefGoogle Scholar
  36. 36.
    Kolda TG, Lewis RM, Torczon V (2003) Optimization by direct search: new perspectives on some classical and modern methods. SIAM Rev 45(3):385–482MathSciNetCrossRefzbMATHGoogle Scholar
  37. 37.
    Hooke R, Jeeves TA (1961) Direct search solution of numerical and statistical problem. J Assoc Comput Mach 8(2):212–229CrossRefzbMATHGoogle Scholar

Copyright information

© Springer-Verlag London 2016

Authors and Affiliations

  1. 1.Faculty of Mechanical Engineering, Department for Machine and Product DesignBudapest University of Technology and EconomicsBudapestHungary

Personalised recommendations