Open Access Open Access  Restricted Access Subscription or Fee Access

Accurate Machine-Settings for the Face-Milling of Hypoid Gears


(*) Corresponding author


Authors' affiliations


DOI: https://doi.org/10.15866/ireme.v11i12.14194

Abstract


A mathematical model of the machine-settings for the face-milling of hypoid gears using accurate cutter system and a generic spiral bevel/hypoid face-milling machine is developed. Accurate cutter system is considered, which contains the inside and outside blades with pre-determined rake, relief, and blade angles in order to generate the cutter system envelope. Since, the machine-settings are based on the tangency between the gear flank and the cutter sweep envelope geometry and gear flank is sensitive to the cutter sweep geometry, therefore, the machine-settings are also sensitive to the cutter system geometry. Numerical applications for specific gear geometry are applied, in which machine-settings are calculated and compared with the previous research results. In the end of the article, a simulation was performed to generate gear tooth surfaces. Surface deviation between the gear teeth generated with the machine-settings for the simplified cutter system and the accurate cutter system are compared and the conclusion is drawn that the rake face of the blades in the cutter system has influence on the machine-settings. Due to the use of an accurate cutter system, the hypoid gears produced using this model are accurate and reduce the need of corrections in the machine-settings.
Copyright © 2017 Praise Worthy Prize - All rights reserved.

Keywords


Hypoid Gear; Face-Milling; Machine Settings; Cutter System; Surface Deviation

Full Text:

PDF


References


FL. Litvin, A. Fuentes, Gear Geometry and Applied Theory (2nd edition, Cambridge University Press, 2004).

FL. Litvin, Y. Gutman, Method of synthesis and analysis for hypoid gear-drives of "Formate" and "Helixform"; Part 1-3, ASME Journal of Mechanical Design, Vol. 103, pp. 83-88, 1981.
http://dx.doi.org/10.1115/1.3254890

FL. Litvin Y. Zhang, M. Lundy, C. Heine, Determination of settings of a tilted head cutter for generation of hypoid and spiral bevel gears, ASME Journal of Mechanical Design, Vol. 110, n. 4, pp. 495-500, 1988.
http://dx.doi.org/10.1115/1.3258950

M. Wasif, ZC. Chen, SM. Hasan, Determination of cutter head geometry for the face milling of hypoid gears, International Journal of Advanced Manufacturing Technology, Vol. 86, n. 9, pp. 3081-3090, 2016.
http://dx.doi.org/10.1007/s00170-016-8430-x

TJ. Krenzer, Computer aided corrective machine settings for manufacturing bevel and hypoid gear sets, Technical papers: Fall Technical Meeting, Washington DC, USA, 1984.

G. Gosselin, Corrective machine settings of spiral-bevel and hypoid gears with profile deviations, World Congress on Gearing and Power Transmission, Paris, Fance, 1999.

G. Gosselin et al., Identification of the Machine Settings of Real Hypoid Gear Tooth Surfaces, ASME Journal of Mechanical Design Vol. 120, pp. 429-440, 1998.
http://dx.doi.org/10.1115/1.2829170

G. Gosselin, L. Cloutier, The Generating Space for Parabolic Motion Error Spiral Bevel Gears Cut by the Gleason Method, ASME Journal of Mechanical Design, Vol. 115, pp. 483-489, 1993.
http://dx.doi.org/10.1115/1.2919215

V. Simon, Optimal Machine Tool Setting for Hypoid Gears Improving Load Distribution, ASME Journal of Mechanical Design, Vol. 123, pp. 577-582, 2001.
http://dx.doi.org/10.1115/1.1414129

V. Simon, Machine-Tool Settings to Reduce the Sensitivity of Spiral Bevel Gears to Tooth Errors and Misalignments, ASME Journal of Mechanical Design, Vol. 130, pp. 082603-1-10, 2008.
http://dx.doi.org/10.1115/1.2936903

V. Simon, Advanced Manufacture of Spiral Bevel Gears on CNC Hypoid Generating Machine, ASME Journal of Mechanical Design, Vol. 132, pp. 031001-1-8, 2010.
http://dx.doi.org/10.1115/1.4001130

V. Simon, Generation of Hypoid Gears on CNC Hypoid Generator, ASME Journal of Mechanical Design, Vol. 133, pp. 121003-1-9, 2011.
http://dx.doi.org/10.1115/1.4005232

IG. Perez, A. Fuentes, K. Hayasaka, Analytical Determination of Basic Machine-Tool Settings for Generation of Spiral Bevel Gears From Blank Data, ASME Journal of Mechanical Design, Vol. 132, pp. 101002-1-11, 2010.
http://dx.doi.org/10.1115/1.4002165

HJ. Stadtfeld, The Ultimate Motion Graph, ASME Journal of Mechanical Design, Vol. 122, pp. 317-322, 2000.
http://dx.doi.org/10.1115/1.1286124

Q. Fan, Tooth Surface Error Correction for Face-Hobbed Hypoid Gears, ASME Journal of Mechanical Design, Vol. 132, pp. 011004-1-8, 2010.
http://dx.doi.org/10.1115/1.4000646

S. Xie, A genuine face milling cutter geometric model for spiral bevel and hypoid gears, International Journal of Advanced Manufacturing Technology, Vol. 67. n. 9-12, pp. 2619-2616, 2013.
http://dx.doi.org/10.1007/s00170-012-4678-y

Y. Zhang, H. Yan, New methodology for determining basic machine settings of spiral bevel and hypoid gears manufactured by duplex helical method, Mechanism and Machine Theory, Vol. 100, pp. 283-295, 2016.
http://dx.doi.org/10.1016/j.mechmachtheory.2016.02.015

H. Ding, J. Tang, J. Zhong, An accurate model of high-performance manufacturing spiral bevel and hypoid gears based on machine setting modification, Journal of Manufacturing Systems, Vol. 41, pp. 111-119, 2016.
http://dx.doi.org/10.1016/j.jmsy.2016.08.004

H. Ding, J. Tang, J. Zhong, Z. Zhou, A hybrid modification approach of machine-tool setting considering high tooth contact performance in spiral bevel and hypoid gears, Journal of Manufacturing Systems, Vol. 41, pp. 228-238, 2016.
http://dx.doi.org/10.1016/j.jmsy.2016.09.003

A. Fuentes-Aznar, R. Ruiz-Orzaezb, I. Gonzalez-Perezb, Numerical approach for determination of rough-cutting machine-tool settings for fixed-setting face-milled spiral bevel gears, Mechanism and Machine Theory, Vol. 112, pp. 22-42, 2017.
http://dx.doi.org/10.1016/j.mechmachtheory.2017.01.010

I. Gonzalez-Pereza, A. Fuentes-Aznarb, Analytical determination of basic machine-tool settings for generation of spiral bevel gears and compensation of errors of alignment in the cyclo-palloid system, International Journal of Mechanical Sciences, Vol. 120, pp. 91-104, 2017.
http://dx.doi.org/10.1016/j.ijmecsci.2016.11.018

M. Wasif, ZC. Chen, An accurate approach to determine the cutting system for the face milling of hypoid gears, International Journal of Advanced Manufacturing Technology Vol. 84, n. 9, pp. 1873-1888, 2015.
http://dx.doi.org/10.1007/s00170-015-7823-6

AGMA, Design Manual for Bevel Gears, ANSI/AGMA, USA, 2005.


Refbacks

  • There are currently no refbacks.


Please send any question about this web site to info@praiseworthyprize.com
Copyright © 2005-2024 Praise Worthy Prize