Transfer of the Method for the psychoacoustic Design of Ground Bevel Gears extended by the Application of a Targeted Micro Geometry Scatter

对齿轮和变速器的要求是由立法等外部条件以及世界市场上的竞争情况决定的。通过减少所涉及的质量和通过新材料增加承载能力，可以实现对更高功率密度的持续需求，以提高效率。此外，传输的一个主要要求是低噪声水平。特别是锥齿轮，由于修改值较高，重合率相对较低，通常被描述为噪音严重。与磨齿锥齿轮相比，搭接的锥齿轮被认为更安静或更平滑。目前的研究表明，与制造相关的微观几何分散和节距偏差可以确定为根本原因。相比之下，磨齿锥齿轮与制造的几何形状相比，具有高再现性和低螺距偏差。几何图形的高再现性可能会导致色调噪声谱。目标螺距偏差的实施用于风扇应用，以降低转子叶片频率的高次谐波的幅度。在齿轮应用中，避免了因音调降低而引起的节距偏差，因为它可能会导致过早啮合，从而导致承载能力下降。本研究项目的目的是将锥齿轮的心理声学设计方法应用于汽车上。因此，现有的轮齿啮合动态仿真和齿轮心理声学设计方法为本项目提供了基础，并将扩展到完整寻齿的模拟，以实现通过定向地形散射来提高背景噪声水平。地形散射被用来降低噪声频谱的音调。利用基于有限元的齿面接触分析，实现了齿轮组的模拟，每个齿具有单独的微观几何。为了保证工艺的生产率，需要在不增加修整操作的情况下实现地形散布的制造工艺。此外，有必要定义微观几何散度，以避免对承载能力的不利影响。传授的方法和获得的知识将应用于汽车变速器，并将通过试验台试验和车辆测量进行验证。计划中的研究项目的结果是一种基于目标地形散射的锥齿轮声学性能优化的新方法。

The requirement on gears and transmissions are determined by external conditions as the legislation as well as the competitive situation on the world market. The continuous demand for higher power densities for the increase of the efficiency can be achieved by a reduction of the involved masses and by an increased load-carrying capacity via new materials. Furthermore, a major requirement by the transmission is a low noise level. Especially bevel gears, with comparatively low contact ratios because of the high values for the modifications, are often described as noise critical.Lapped bevel gear set are perceived as being quieter or smoother compared to ground bevel gear sets. Current investigations lead to the fact that the manufacturing related microgeometry scatter and pitch deviation can be identified as the root cause. Ground bevel gears in contrast have a high reproducibility of the manufactured geometry with low pitch deviations. The high reproducibility of the geometry may lead to a tonal noise spectrum. The implementation of targeted pitch deviations is used for fan applications to reduce the amplitudes of higher harmonics of the rotor blade frequency. In gear applications, the pitch deviation for reduction of tonality is avoided, as it may lead to premature tooth meshing which lead to a decrease of the load-carrying capacity. The aim of this research project is the transfer of the method for psychoacoustic design of bevel gears on an automotive application. Therefore, the existing methods of the dynamic simulation of the tooth mesh and the psychoacoustic design of gears provide the basis for the project and will be extended for the simulation of a complete tooth hunt in order to implement an increase of the background noise level by a targeted topography scatter. The topography scatter is used to reduce the tonality of the noise spectrum. Using the FE-based tooth contact analysis, a simulation of a gear set with individual micro geometries for each tooth is realized. In order to assure the productivity of the process The manufacturing process of the topography scatter needs to be realized without an extra dressing operation. Furthermore, it is necessary to define the microgeometry scatter which avoids disadvantages for the load-carrying capacity. The transferred methods and the gained knowledge will be applied on an automotive transmission and will be validated by test rig trials and vehicle measurements. The result of the planned research project is a novel method for optimizations of the acoustic behavior of bevel gears based on a targeted topography scatter.