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As is well known in involute gearing, â€śperfectâ€ť involute gears never work perfectly in the real world. Flank modifications are often made to overcome the influences of errors coming from manufacturing and assembly processes as well as deflections of the system. The same discipline applies to hypoid gears.
Optimizing the running behavior of bevel and hypoid gears means improving both noise behavior and load carrying capacity. Since load deflections change the relative position of pinion and ring gear, the position of the contact pattern will depend on the torque. Different contact positions require local 3-D flank form optimizations for improving a gear set.
A pair of spur gears generally has an effective lead error which is caused, not only by manufacturing and assembling errors, but also by the deformations of shafts, bearings and housings due to the transmitted load. The longitudinal load distribution on a contact line of the teeth of the gears is not uniform because of the effective lead error.
In some gear dynamic models, the effect of tooth flexibility is ignored when the model determines which pairs of teeth are in contact. Deflection of loaded teeth is not introduced until the equations of motion are solved. This means the zone of tooth contact and average tooth meshing stiffness are underestimated, and the individual tooth load is overstated, especially for heavily loaded gears. This article compares the static transmission error and dynamic load of heavily loaded, low-contact-ratio spur gears when the effect of tooth flexibility has been considered and when it has been ignored. Neglecting the effect yields an underestimate of resonance speeds and an overestimate of the dynamic load.
This paper discusses the influence of tip relief, root relief, load modification, end relief and their combinations on gear stresses and transmission errors due to shaft deflections.
The development of a new gear strength computer program based upon the finite element method, provides a better way to calculate stresses in bevel and hypoid gear teeth. The program incorporates tooth surface geometry and axle deflection data to establish a direct relationship between fillet bending stress, subsurface shear stress, and applied gear torque. Using existing software links to other gear analysis programs allows the gear engineer to evaluate the strength performance of existing and new gear designs as a function of tooth contact pattern shape, position and axle deflection characteristics. This approach provides a better understanding of how gears react under load to subtle changes in the appearance of the no load tooth contact pattern.
One of the most effective methods in solving the edge loading problem due to excess misalignment and deflection in aerospace actuation gearing is to localize tooth-bearing contact by crowning the teeth. Irrespective of the applied load, if the misalignment and/or deflection are large enough to cause the contact area to reduce to zero, the stress becomes large enough to cause failure. The edge loading could cause the teeth to break or pit, but too much crowning may also cause the teeth to pit due to concentrated loading. In this paper, a proposed method to localize the contact bearing area and calculate the contact stress with crowning is presented and demonstrated on some real-life examples in aerospace actuation systems.
An analytical method is presented to predict the shifts of the contact ellipses on spiral bevel gear teeth under load. The contact ellipse shift is the motion of the point to its location under load. The shifts are due to the elastic motions of the gear and pinion supporting shafts and bearings. The calculations include the elastic deflections of the gear shafts and the deflections of the four shaft bearings. The method assumes that the surface curvature of each tooth is constant near the unloaded pitch point. Results from these calculations will help designers reduce transmission weight without seriously reducing transmission performance.
A best practice in gear design is to limit the amount of backlash to a minimum value needed to accommodate manufacturing tolerances, misalignments, and deflections, in order to prevent the non-driving side of the teeth to make contact and rattle. Industry standards, such as ANSI/AGMA 2002 and DIN3967, provide reference values of minimum backlash to be used in the gear design. However, increased customers' expectations in vehicle noise eduction have pushed backlash and allowable manufacturing tolerances to even lower limits. This is especially true in the truck market, where engines are quieter because they run at lower speeds to improve fuel economy, but they quite often run at high torsional vibration levels. Furthermore, gear and shaft arrangements in truck transmissions have become more complex due to increased number of speeds and to improve efficiency. Determining the minimum amount of backlash is quite a challenge. This paper presents an investigation of minimum backlash values of helical gear teeth applied to a light-duty pickup truck transmission. An analytical model was developed to calculate backlash limits of each gear pair when not transmitting load, and thus susceptible to generate rattle noise, through different transmission power paths. A statistical approach (Monte Carlo) was used since a significant number of factors affect backlash, such as tooth thickness variation; center distance variation; lead; runout and pitch variations; bearing clearances; spline clearances; and shaft deflections and misalignments. Analytical results identified the critical gear pair, and power path, which was confirmed experimentally on a transmission. The approach presented in this paper can be useful to design gear pairs with a minimum amount of backlash, to prevent double flank contact and to help reduce rattle noise to lowest levels.
Point-surface-origin (PSO) macropitting occurs at sites of geometric stress concentration (GSC) such as discontinuities in the gear tooth profile caused by micropitting, cusps at the intersection of the involute profile and the trochoidal root fillet, and at edges of prior tooth damage, such as tip-to-root interference. When the profile modifications in the form of tip relief, root relief, or both, are inadequate to compensate for deflection of the gear mesh, tip-to-root interference occurs. The interference can occur at either end of the path of contact, but the damage is usually more severe near the start-of-active-profile (SAP) of the driving gear.
Service performance and load carrying capacity of bevel gears strongly depend on the size and position of the contact pattern. To provide an optimal contact pattern even under load, the gear design has to consider the relative displacements caused by deflections or thermal expansions expected under service conditions. That means that more or less lengthwise and heightwise crowning has to be applied on the bevel gear teeth.
The capabilities and limitations of manufacturing gears by conventional means are well-known and thoroughly documented. In the search to enhance or otherwise improve the gear-making process, manufacturing methods have extended beyond chip-cutting - hobbing, broaching, shaping, shaving, grinding, etc. and their inherent limitations based on cutting selection and speed, feed rates, chip thickness per tooth, cutting pressure, cutter deflection, chatter, surface finish, material hardness, machine rigidity, tooling, setup and other items.
This paper addresses the lubrication of helical gears - especially those factors influencing lubricant film thickness and pressure. Contact between gear teeth is protected by the elastohydrodynamic lubrication (EHL) mechanism that occurs between nonconforming contact when pressure is high enough to cause large increases in lubricant viscosity due to the pressure-viscosity effect, and changes of component shape due to elastic deflection. Acting together, these effects lead to oil films that are stiff enough to separate the contacting surfaces and thus prevent significant metal-to-metal contact occurring in a well-designed gear pair.
This article presents an analysis of asymmetric tooth gears considering the effective contact ratio that is also affected by bending and contact tooth deflections. The goal is to find an optimal solution for high performance gear drives, which would combine high load capacity and efficiency, as well as low transmission error (which affects gear noise and vibration).
In many gear transmissions, tooth load on one flank is significantly higher and is applied for longer periods of time than on the opposite one; an asymmetric tooth shape should reflect this functional difference. The advantages of these gears allow us to improve the performance of the primary drive tooth flanks at the expense of the opposite coast flanks, which are unloaded or lightly loaded during a relatively short work period by drive flank contact and bending stress reduction. This article is about the microgeometry optimization of the spur asymmetric gearsâ€™ tooth flank profile based on the tooth bending and contact deflections.