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Influence of the manufacturing method on the running behavior of beveloid gears

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Abstract

Beveloid gears, also known as conical involute gears, gain more and more importance in industrial practice. They are based on cylindrical gears, but have a variable profile shift along their tooth width. For some time, beveloid gears have been applied to marine transmissions (Winkler 2002; Zhu et al. in Chin J Mech Eng 25:328–337, 2012), but in the last years they have been used increasingly in the automotive industry (Börner et al. in Gear Technol 6:28–35, 2005; Alxneit 2010). A crucial step of the manufacturing process is the grinding process that is necessary to achieve high load carrying capacity and low noise vibration harshness (NVH). During the grinding process the micro-geometry of the tooth flanks can be modified in order to increase the gear quality. For the generation grinding process of beveloids, two types of machine kinematics and two tool concepts are known. The different machine kinematics and tool concepts may lead to unintentional changes in micro-geometry of the flanks which has an impact on load carrying capacity and NVH qualities of the gear. Up to now, no research has been made to quantify the influence of the machine kinematics and the tool concept on load carrying capacity and NVH. Therefore, these influences are analyzed in this work by simulating the gear manufacturing with the help of the two known machine kinematics as well as the two known tool concepts and by meshing the simulated gears in an FE-based tooth contact analysis (TCA). The results of the TCA are parameters regarding the running behavior which are analyzed and compared for the four aforementioned manufacturing concepts.

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Abbreviations

a:

Distance between axles

b:

Gear width

Ca :

Tip relief

CVα :

Twist

Cβ :

Lead crowning

d0 :

Tool radius

D1 :

Mounting distance of gear 1

D2 :

Mounting distance of gear 2

da :

Tip diameter

dCa :

Diameter of the tip relief start

FE:

Finite elements

fHα :

Profile angle modification

fHβ :

Helix angle modification

H:

Heel

haP0 :

Addendum

hfP0 :

Dedendum

NVH:

Noise vibration harshness

M:

Middle

mn :

Normal module

T:

Toe

T1 :

Torque at gear 1

TCA:

Tooth contact analysis

z:

Number of teeth

Σ:

Crossing angle

xe :

Generation profile shift

z0 :

Number of starts

αn, αP0 :

Normal pressure angle

β:

Helix angle

εγ :

Contact ratio

θa:

Tip cone angle

θf :

Root cone angle

ρaP0 :

Tip radius

σFP :

Flank pressure

σv :

Maximal von mises stress

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Acknowledgments

The investigations described in the present paper were conducted as a part of a project sponsored by Deutsche Forschungsgemeinschaft (DFG).

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Authors and Affiliations

  1. Chair for Machine Tools, Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Aachen, Germany

    Christian Brecher, Markus Brumm, Florian Hübner & Jannik Henser

Authors
  1. Christian Brecher
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  2. Markus Brumm
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  3. Florian Hübner
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  4. Jannik Henser
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Correspondence to Jannik Henser.

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Brecher, C., Brumm, M., Hübner, F. et al. Influence of the manufacturing method on the running behavior of beveloid gears. Prod. Eng. Res. Devel. 7, 265–274 (2013). https://doi.org/10.1007/s11740-012-0442-2

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  • DOI: https://doi.org/10.1007/s11740-012-0442-2

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