Optimization of Gear Design and Manufacture

Abstract

In this study a method is proposed for the optimization of the design and manufacture of gears. Optimal modifications are introduced into gear tooth surfaces in order to improve the operating characteristics of the gear pair, namely, to reduce the tooth contact pressure and the transmission errors, and to decrease the sensitivity of the gear pair to errors in tooth surfaces and to the relative positions of the mating members. The optimal modifications of gear tooth surfaces are introduced by the application of the adequate machine tool settings and tool geometry. An optimization methodology is applied to systematically define optimal tool geometry and machine tool settings to simultaneously minimize tooth contact pressures and angular displacement error of the driven gear. The use of a CNC gear manufacture machine makes it possible to perform nonlinear correction motions for cutting the optimized gears. Effectiveness of the method was demonstrated by using a spiral bevel gear example. Significant reductions in the maximum tooth contact pressure and in the transmission errors were obtained.