Computerized determination of the qualified region of main design parameters of face-milled hypoid gears with low shaft angle

Abstract

The influence of main design parameters of hypoid gears with low shaft angle, namely, the offset, shaft angle, cutter radius, gear ratio, and the spiral angle of wheel, on the geometrical morphology the gear tooth surfaces has been investigated. Checks for obtaining appropriate top-land widths and spiral angles at the toe and heel sides have been developed and applied. The limits for the main design parameters that yield non-adequate tooth surfaces because- of top-land pointing, undercutting, or having a negative value of the spiral angle of wheel at the toe side have been investigated based on the results obtained by the simulation of a large number of cases of design. A specific computerized flow chart has been designed to iterate among the main design parameters to obtain a qualified region for them. With those results, a limiting graph has been proposed to get the list of recommended values of main design parameters and provide a reference for their selection. Finally, the results of loaded tooth contact analysis of two cases of design arbitrarily chosen from the proposed limiting graph of recommended values are shown to verify its applicability to yield to successful designs with favorable conditions of meshing and contact.