Sensitivity Analysis and Surface-Deviation Minimization of ZK-Type Dual-Lead Worm Gear Drives

Abstract

This work uses the mathematical model of ZK-type dual-lead worm gear drive proposed in our recent work (1998). Based on the proposed mathematical model, coordinates and unit normals of the worm gear surface grid points can be determined and a data file subsequently formed. The data file is considered as the theoretical tooth surface data and then input into the computer of a three-dimensional coordinate measurement machine (3-D CMM) to numerically calculate the surface deviations of a real-cut worm gear. In addition, a computerized tooth surface measurement model compatible with the 3-D CMM is developed. Sensitivity analysis is also performed on machine-tool settings and tool-profile errors to the generated gear tooth surface variations. Minimization on gear tooth surface variations can be determined by applying the proposed measurement and calculation methods. In addition, optimum machine tool settings and tool-profile modifications are obtained by applying the developed computer simulation softwares. Moreover, the singular value decomposition (SVD) and sequential quadratic programming (SQP) methods are compared to establish the optimum machine-tool settings and resolve the minimum surface deviation problems.