An analytical method for the meshing performance of deviation surface of spiral bevel gear based on a one-dimensional probe

Abstract

The meshing performance is a significant indicator for evaluating the machining quality of spiral bevel gear. The flank contact accuracy (FCA) and flank geometric accuracy (FGA) are important aspects of meshing performance, and both are indispensable. In the actual production process, due to the lack of professional meshing performance analysis (MPA) software, the flank geometric structure cannot be reflected based on the FCA, and the actual meshing state cannot be reflected by the FGA, which cannot meet the manufacturing requirements of high-quality gear. Therefore, a MPA method for deviation surface of spiral bevel gear is proposed based on the gear measuring center using a one-dimensional probe. By constructing the deviation surface, the flank meshing model is established, and the meshing parameters are determined. Aiming at the complexity of solving the meshing model, a method for decreasing the dimension of the meshing equations is proposed by establishing the mathematical relationship between the rotation angle and the normal vector, which improves the solution accuracy of the meshing point. The intersection points of the adjacent transmission error curves are taken as the meshing in and out points, and then the actual position of the contact pattern is accurately determined. The instantaneous contact ellipse is obtained by using the method of a cylindrical surface intercepting the deviation surfaces, which not only simplifies the solution algorithm, but also obtains the contact pattern more in line with the actual situation. Finally, the transmission error and contact pattern are digitally characterized. The experimental results show that the digital and actual patterns have good consistency. Flank geometry and gear meshing are organically linked based on the proposed method, and the actual meshing state can be predicted according to the flank topology deviation, which provides important theoretical support for the improvement of the machining quality and meshing performance of the spiral bevel gear.