Transfer of the local calculation method of the tooth root load carrying capacity of beveloid gears onto an industrial application with crossing axes

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Beveloid gears can be used with parallel, crossing and skewed axes. Industrial applications, especially in the automobile industry, use beveloid gears with crossing or skewed axes. Today, calculation methods of the tooth root carrying capacity of beveloid gears exist. The state of the art also includes calculation methods for the tooth root stress of beveloid gears with crossing or skewed axes. Up till today, no validated calculation method exists for the tooth root load carrying capacity of beveloid gears with crossing or skewed axes with consideration of the local material and strain properties, the gear flank geometry as well as the manufacturing deviations and tolerances. Therefore, the results of the preceding DFG-project "Development and Verification of a method for calculation the tooth root load carrying capacity of beveloid gears" should be transferred to an industrial application with crossing axes and made applicable for crossing and skewed axes. Thus, unused design potential for beveloid gears can be used in order to improve the operational behavior and reduce the manufacturing costs. Based on the local approach necessary tolerance fields for the gear geometry can be defined.The objective of the research project is to develop and apply a validated, industry applicable method for optimizing the gear geometry and manufacturing tolerances for beveloid gears with crossing axes in order to enhance the tooth root load carrying capacity. The method is able to predict the tooth root load carrying capacity with consideration of manufacturing deviations (twist). The result of the research project is a method which helps the design engineer in the gear industry to find the optimal gear geometry of beveloid gears regarding the tooth root load carrying capacity. The method should imply all the significant effects, e.g. manufacturing deviations, onto the tooth root load carrying capacity. Based on the method an optimization of the tooth root load carrying capacity with consideration of all manufacturing deviations is possible. The results of the local calculation approach and the experiments can be used to enhance the standard reference and therefore, improve the industrial design process and help finding the optimal gear design regarding the tooth root load carrying capacity. Thus, over-engineering and failed design regard the tooth root load carrying capacity can be avoided.