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

一种特殊的齿轮类型变得越来越重要，那就是锥齿轮，也被称为圆锥渐开线齿轮。这在很大程度上是因为它们能够实现轴之间的小交叉角，并且可以在传统的磨齿机上经济地生产。例如，多年来，锥齿轮已在海洋应用中使用。近年来，锥齿轮在汽车行业的使用有所增加。这里使用锥齿轮，例如在四轮驱动中，将扭矩和旋转从变速箱的输出传递到可能不平行的前轴。齿轮的运行行为通常以承载能力和噪声振动粗糙度(NVH)为特征。传统的侧翼调整，如凸度和角度调整，可以用来优化跑动行为。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位置，不可能通过标准修形来实现全线接触而不是点接触。线接触使齿面的载荷分布更均匀，从而降低赫兹应力。在现有的实现线接触的设计中，没有考虑后刀面的加工性。此外，还没有测量和公差这些拓扑修形的方法。对于直齿圆柱齿轮和斜齿轮，存在制造拓扑面修形的方法。但这种制造方法的工艺稳定性和利润率较低。因此，像连续生成磨削这样的标准制造工艺更适合于满足经济和技术要求。此外，还没有面向功能的方法来容忍拓扑侧翼的修改。因此，考虑到现有技术的现状，本研究的目的是开发和验证一种通用的面向功能的方法，在考虑可制造性的情况下进行锥面修形的设计。现有侧翼修改的定义以这样的方式扩展，即针对侧翼的每个点局部定义拓扑修改。该方法的目的是考虑标准制造工艺的约束，优化锥齿轮的运行行为(承载能力和NVH)。

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.