Fundamental research on performance and failure prediction for hypoid/bevel gears

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(1) The construction of hypoid/bevel gear cutting machine is analyzed and a mathematical method to generate the tooth flank form as function of machine setting values is developed.(2) The computer program to simulate the power transmitting characteristics of bevel and hypoid gears as functions of gear dimensions, machine setting summary, transmitting torque and state of gear alignment is developed. (3) Hypoid gears of long, short, bias-in and bias-out contact pattern were produced and loading test of these gears was carried out. The results of the simulation are examined by this experiment. (4) The change of the meshing frequency component of gear vibration with progress of crack along tooth fillet is analyzed by this simulation to explain the cause of this phenomenon. (5) Through these investigations the reliability of the simulation for the power transmitting characteristics of bevel/hypoid gears is established.