Abstract
To avoid edge contact and stress concentration on the tooth surface of hypoid gear pairs machined by the duplex helical method for the drive axle of heavy-duty vehicles, a four-segment tool profile was designed for the simultaneous modification of the concave and convex surfaces of the pinion. First, a geometric model of the four-segment tool profile was established. Second, a mathematical model of the duplex helical method based on the four-segment tool profile was established, and a method for solving the tooth surface generated by the connecting points of the four-segment tool profile was presented. Finally, loaded tooth contact analysis based on finite element method was used to analyse the meshing performance of the gear pair obtained by the four-segment tool profile modification. The results of the original and modified gear pairs were compared. The tooth surface modification inhibited edge contact, improved the stress distribution, and decreased the maximum contact stress of the tooth surfaces, thereby improving the fatigue and wear life of the gear pair.
Highlights
The hypoid gear pair of the heavy–duty vehicle drive axle has the characteristics of heavy load and high speed when working
The finite element method of loaded tooth contact analysis is used to analyze the meshing performance of the gear pair obtained by the four-segment tool profile modification, and the results are compared with the original gear pair
The meshing performance of the original and modified gear pairs is analyzed by combining the Loaded tooth contact analysis (LTCA) based on finite element analysis (FEA)
Summary
The hypoid gear pair of the heavy–duty vehicle drive axle has the characteristics of heavy load and high speed when working. The positions of the connecting points A and B of the four-segment tool profile shown in Fig. 1 in the Sp coordinate system can be determined by the parameters ha, hc and αp. 2.2 The Solution of tooth surface generated by connecting points of four-segment tool profile In order to obtain the tooth surface space coordinate points, the tooth surface needs to be discretized according to the geometric parameters of the gear pair, that is, the tooth surface is divided into uniform grid points. It is necessary to solve the tooth surface boundary line generated by the connection points between the tool profiles. The entire tooth surface can be obtained by connecting the tooth surface developed by the four segment tool profile
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