Abstract
The procedure of computerized generation and the results of simulation of meshing and stress analysis of face gear drives manufactured by circular cutters without considering the feed motion of the circular cutters is presented. A cutter profile tilt angle is introduced and investigated to approximate the generating surfaces of the circular cutter as much as possible to those of the theoretical reference shaper. Six different cases of design are considered to investigate the influence of design parameters on the contact patterns of the gear tooth surfaces. The results include the distribution of deviations of the face gear tooth surfaces with respect to the reference surface geometry generated by a shaper, the contact patterns, function of transmission errors, and the evaluation of stresses all over two cycles of meshing. The analysis of the results shows that the surface deviations due to the generation of the face gear by circular cutters can result in edge contacts, interference, and high stress concentration. However, if the appropriate design parameters for the circular cutters are properly evaluated as a result of simulation and applied as proposed here, the mechanical behavior of the face gear, by means of contact patterns and evolution of stresses can be as good as for the standard geometry of the face gears.
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