Abstract
The competitiveness of gearboxes is significantly influenced by their performance ability. Increasing the tooth root load capacity has always been in focus of current research because in case of a failure of the gearwheel due to a tooth root fracture, the complete gearbox fails. This paper presents a new calculation method that enables the optimization of hob geometries within a few minutes so that they lead to reduced stresses in the tooth root fillet of spur gears. This results in reductions of the maximum tooth root stress of 10% and more for most gearwheels. The manufacturing costs for the optimized hob are only influenced slightly. In order to increase the computational speed compared to purely FE-based optimization methods, the present paper shows a method in which the decisive part of the optimization process is based on an analytical equation which are derived by a small number of FE-calculations.
Highlights
Spur gears are one of the most important machine elements and essential in so many applications
Previous solutions to increase the tooth root load capacity can be divided into 3 groups: materials, manufacturing processes and tooth root geometry
This paper shows a simulation method for the optimization of the tooth root geometry of spur gears milled by a hob
Summary
Spur gears are one of the most important machine elements and essential in so many applications. The maximum stress which is relevant for the calculation of the tooth root load capacity does no longer arise at the 30° tangent of the tooth root fillet, as it is firmly assumed in the standards For this reason, the standardized calculation rules are no longer valid and other calculation methods must be used. A further focus of the presented optimization process is to ensure economical gearwheel manufacturing by gear hobbing compared to the expensive production by 5-axis milling or profile grinding. For this reason, geometry optimization in the context of this method does not directly affect the tooth root fillet of the spur gear,. It can be recognized by the fact that the tooth root stresses within the optimized tooth root fillet are constant over a large section
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