Abstract
To improve the meshing performance and increase the bearing capacity and service life of spiral gear pairs, a cutterhead approximation machining method based on controlling geometric topological deviations was proposed to solve the problem where line contact spiral bevel gears with tapered teeth depth cannot be machined by cutterheads. First, a mathematical model of the line contact conjugate flank was established, and the geometric topological deviations model of the comparison between the machining tooth flank and the theoretical tooth flank was obtained. Second, the deviation of each tooth flank point was calculated by the topological differential calculus analysis. Finally, with the machining tooth flank approaching the theoretical tooth flank as the modification objective, the additional cutting motions and machining compensation parameters of cutterheads were obtained to control the machining tooth flank deviations and reduce them to the allowable deviations of the theoretical tooth flank, and the cutterhead approximation machining of line contact spiral bevel gear pairs with tapered teeth depth was realized. The contact simulation analysis and rolling test verified the correctness of the line contact conjugate flank model and the feasibility of the cutterhead approximation machining method.
Similar content being viewed by others
Availability of data and material
All data generated or analyzed during this study are included in this article.
References
Gleason Works (1971) Method for designing hypoid blanks. Rochester, New York
Institute of Tianjin Gear Generator (1989) Translation works of Gleason spiral bevel gear technical documentation. China Machine Press, Beijing
Gleason Works (1971) Calculation instructions generated spiral bevel gears duplex helical method. Rochester, New York
Litvin FL, Lee HT (1989) Generation and tooth contact analysis of spiral bevel gears with predesigned parabolic functions of transmission error. NASA Lewis Research Center, Chicago
Litvin FL, Zhang Y (1991) Local synthesis and tooth contact analysis of face-milled spiral bevel gears. NASA Lewis Research Center, Chicago
Litvin FL, Fuentes A (2004) Gear geometry and applied theory. Cambridge University Press, Cambridge
Shih YP (2010) A novel ease-off flank modification methodology for spiral bevel and hypoid gears. Mech Mach Theory 45(8):1108–1124. https://doi.org/10.1016/j.mechmachtheory.2010.03.010
Shih YP, Sun ZH, Lai KL (2017) A flank correction face-milling method for bevel gears using a five-axis CNC machine. Int J Adv Manuf Technol 91(9–12):3635–3652. https://doi.org/10.1007/s00170-017-0032-8
Artoni A, Gabiccini M, Guiggiani M (2008) Nonlinear identification of machine settings for flank form modifications in hypoid gears. J Mech Des 130(11):112602. https://doi.org/10.1115/1.2976454
Artoni A, Bracci A, Gabiccini M, Guiggiani M (2009) Optimization of the loaded contact pattern in hypoid gears by automatic topology modification. J Mech Des 131(1):011008. https://doi.org/10.1115/1.3013844
Gabiccini M, Artoni A, Guiggiani M (2012) On the identification of machine settings for gear surface topography corrections. J Mech Des 134(4):041004. https://doi.org/10.1115/1.4006002
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 61:84–101. https://doi.org/10.1016/j.mechmachtheory.2012.10.005
.Nie SW, Deng J, Deng XZ, ZhangH, Cao XM, Li JB (2017) Tooth surface topology modification and processing parameters calculation for spiral bevel gears. Journal of Aerospace Power 32(8):2009–2016 https://doi.org/10.13224/j.cnki.jasp.2017.08.026
Nie SW, Deng J, Deng XZ, Geng LL (2018) A flank modification method for spiral bevel gears based on mismatch topography adjustment. Journal of Advanced Mechanical Design Systems and Manufacturing 12(2):18–00141. https://doi.org/10.1299/jamdsm.2018jamdsm0057
Mu YM, Li WL, Fang ZD (2019) Tooth surface modification method of face–milling spiral bevel gears with high contact ratio based on cutter blade profile correction. Int J Adv Manuf Technol 106(7–8):3229–3237. https://doi.org/10.1007/s00170-019-04738-3
Alvarez A, Lopez de Lacalle LN, Olaiz A, Rivero A (2015) Large spiral bevel gears on universal 5–axis milling machines: a complete process. Procedia Engineering 132:397–404. https://doi.org/10.1016/j.proeng.2015.12.511
Zhou YS, Chen ZC, Tang JY, Liu SJ (2017) An innovative approach to NC programming for accurate five-axis flank milling of spiral bevel or hypoid gears. Comput Aided Des 84:15–24. https://doi.org/10.1016/j.cad.2016.11.003
Sue YH, Li XH (2017) Spread–out helix modified roll of spiral bevel gears and tooth contact analysis. Journal of Tianjin University (Natural Science and Engineering Technology Edition) 50(4):421–428 https://doi.org/10.11784/tdxbz201605042
Efstathiou C, Tapoglou N (2021) A novel CAD–based simulation model for manufacturing of spiral bevel gears by face milling. CIRP J Manuf Sci Technol 33:277–292. https://doi.org/10.1016/j.cirpj.2021.04.004
Hong ZB (2013) New milling method of spiral bevel gears based on generating principle of tooth surface with spherical involute. Dissertation, Jilin University
Garcia-Garcia R, Gonzalez-Palacios MA (2018) Method for the geometric modeling and rapid prototyping of involute bevel gears. Int J Adv Manuf Technol 98(1–4):645–656. https://doi.org/10.1007/s00170-018-2246-9
Ailibao·B, Adayi·X (2019) Research on digital model of spiral bevel gear with linear approximation. Machinery Design & Manufacture (02):230–233 https://doi.org/10.19356/j.cnki.1001-3997.2019.02.058
Sue YH, Yan DS. China, 2020106213596, 2020–06–30
Funding
This work was supported by the National Natural Science Foundation of China (Grant Numbers 51875395).
Author information
Authors and Affiliations
Contributions
All authors contributed to the study’s conception and design. Methodology, data analysis, and validation were performed by Mingyang Wang. Resources and supervision were performed by Yuehai Sun. The first draft of the manuscript was written by Mingyang Wang, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.
Corresponding author
Ethics declarations
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Wang, M., Sun, Y. Cutterhead approximation machining method of line contact spiral bevel gear pairs based on controlling topological deviations. Int J Adv Manuf Technol 121, 1623–1637 (2022). https://doi.org/10.1007/s00170-022-09132-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-09132-0