Modelling method, simulation and experimental verification of hypoid gear involved tooth surface deviation under manufacturing process

Abstract

Tooth surface errors are inevitable in manufacturing process, and directly affect the meshing performance and NVH properties. In this paper, the tooth profile deviation and midpoint tooth pitch error were considered. Firstly, the theoretical tooth surface model was established by simulating the manufacturing process of face-hobbed hypoid gear. Then, a novel modelling method of tooth surface errors was proposed based on the relationship between discrete tooth surface points and measured error points. A solid model and finite element model by using CAD and CAE technologies were developed to study the effects of tooth surface errors and meshing phase on the contact pattern and transmission error. Results show that the gear tooth surface error was the primary factor while the tooth meshing process contributes the least of total transmission error. The peak-to-peak of the transmission error values of pinion and gear with error was 24.786 times higher than standard. The meshing phase of gear had greater impact on the contact pattern. The range of transmission error fluctuation was 210 μrad within different meshing phases. The tooth surface points measurement and rolling experiment were performed and the fluctuation range was around 233.86 μrad with a 10.2% difference.