Development of a General Function Oriented Method to Design Flank Modifications of Beveloids under Consideration of Producibility

一个特殊的齿轮类型，变得越来越重要的是锥齿轮，也被称为锥形渐开线齿轮。这主要是由于它们能够实现轴之间的小交叉角，并且它们可以在传统的磨齿机上经济地生产。锥齿轮已经在例如船舶应用中使用多年。近年来，在汽车行业中使用变截面齿轮已经增加。例如，在四轮驱动系统中，锥齿轮用于将扭矩和旋转从变速箱的输出端传递到可能不平行的前轴。齿轮的运行特性通常以承载能力和噪声振动粗糙度（NVH）为特征。传统的齿侧修改，如冠部和角度修改，可以用于优化运行行为。对于锥齿轮，这种优化达到了极限。由于锥齿轮的几何形状和定位，不可能通过使用标准修改来实现全线接触而不是点接触。线接触导致齿面上更好的载荷分布，这导致赫兹应力减小。在现有的实现线接触的设计中，没有考虑齿面修形的可加工性。此外，还没有测量和容忍这些拓扑修改的方法。对于直齿轮和斜齿轮，存在制造拓扑齿面修改的方法。但这种制造方法的工艺稳定性和盈利能力较低。因此，标准的制造工艺，如连续展成磨削，是最好的，以满足经济和技术要求。此外，不存在容许拓扑侧翼修改的面向功能的方法。因此，拓扑齿面修改的全部潜力没有被完全利用。因此，考虑到现有技术的实际状况，本研究项目的目的是开发和验证一种通用的面向功能的方法，以设计考虑生产率的贝韦洛齿面修改。现有的侧面修改的定义是扩展的方式，拓扑修改的定义局部的侧面的每个点。这种方法的目的是优化的锥齿轮运行行为（承载能力和NVH），考虑到标准制造工艺的约束。

A particular gear type which becomes more and more important is the beveloid gear, also known as conical involute gear. This is manly due to their ability to realize small crossing angles between shafts and they can be produced economically on conventional gear grinding machines. Beveloid gears have been used in marine applications, for example, for many years. In recent years the use of beveloid gears in the automotive sector has increased. Here the beveloid gear is used, for example in four wheel drives to transmit torque and rotation from the output of the gearbox to a front axle that may not be parallel.The running behavior of gears is generally characterized by load carrying capacity and noise vibration harshness (NVH). Conventional flank modifications, like crownings and angle modifications, can be used to optimize the running behavior. For beveloid gears this optimization reaches its limits. Due to the geometry and positioning of beveloid gears it is not possible to realize full line contact instead of point contact by using standard modifications. Line contact leads to a better load distribution on the tooth flanks which leads to decreased Hertzian stresses. In existing designs for realizing line contact the machinability of the flank modifications is not regarded. Furthermore there exist no methods to measure and tolerate these topological modifications.For spur and helical gears exist methods to manufacture topological flank modifications. But the process stability and profitability of this manufacturing method is low. Thus standard manufacturing processes like the continuous generating grinding are preferred to match economical and technical requirements. Additionally there exists no function oriented method to tolerate topological flank modifications. Ergo the full potential of topological flank modifications is not completely utilized.Hence, regarding the actual state of the art, the aim of this research project is to develop and verify a general function oriented method to design flank modifications of beveloids under consideration of producibility. The definition of existing flank modifications is extended in that way that topological modifications are defined locally for each point of the flank. The purpose of this method is the optimization of the beveloid gears running behavior (load carrying capacity and NVH), regarding the constraints of standard manufacturing processes.