Development of a method to determine the main gear data of involute gears with a small shaft angle and offset

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Motivated by innovative fields of application and an increased demand for beveloid gears, a consistent analytical method to design this special gearing is to be developed. In addition to the determination of suitable main gear data, its key benefit is the direct analytical optimization to obtain a conjugated meshing without iterative numerical simulations.Despite great advantages, many applications suitable for beveloid gears are implemented by other concepts with additional design elements. One of the reasons is certainly the lack of know-how or the high effort involved in the necessary use of iterative or simulative tools in the design process. Thus, a consistent analytical method is still lacking that determines suitable main gear data and optimizes the microgeometry in consideration of a predefined mounting position. This research project aims to close this gap by developing a method to design beveloid gears with a small shaft angle and offset economically and in accordance with the requirements. In addition, the generalization of the mathematical approach allows transferability to other types of gearing.The starting point of the proposed research project is an equivalent cylindrical gear, which is pre-dimensioned with respect to the requirements. For these data and the required mounting position, an analytical method is developed to determine the main gear data for beveloid gears with backlash-free meshing and centered point of contact. Based on this, a conjugated meshing or a predetermined contact pattern position and size can be realized by locally adapting the main gear data. Finally, this calculation method is validated theoretically by an extensive parameter study and experimentally by exemplary beveloid gears designed according to this method. In addition, a study shows that the method can also be applied to other types of gearing.The development of this calculation method for beveloid gears and the possible transferability of the mathematical approach to other types of gears are marked by a significant basic research character, from which important findings for the interpretation of involute gears can be gained.