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

一种变得越来越重要的特殊齿轮类型是锥齿轮，也称为圆锥渐开线齿轮。这主要是因为它们能够实现轴之间的小交叉角，并且可以在传统磨齿机上经济地生产。例如，锥齿轮已在船舶应用中使用多年。近年来，锥齿轮在汽车领域的使用有所增加。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。传统的齿面修改（例如凸面和角度修改）可用于优化运行行为。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。线接触可以使齿面上的载荷分布更好，从而降低赫兹应力。在实现线接触的现有设计中，没有考虑侧面修改的可加工性。此外，不存在测量和容忍这些拓扑修改的方法。对于正齿轮和斜齿轮，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，优选使用连续生成磨削等标准制造工艺来满足经济和技术要求。此外，不存在以功能为导向的方法来容忍拓扑侧面修改。因此，拓扑侧面修改的全部潜力没有得到完全利用。因此，考虑到现有技术的实际水平，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，在考虑可生产性的情况下设计斜面侧面修改。现有侧面修改的定义以如下方式扩展：为侧面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限制，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.