Computerized Modeling and Loaded Tooth Contact Analysis of Hypoid Gears Manufactured by Face Hobbing Process

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The face hobbing process has been widely applied in automotive industry. But so far few analytical tools have been developed. This makes it difficult for us to optimize gear design. To settle this situation, this study aims at developing a computerized tool to predict the running performances such as loaded tooth contact pattern, static transmission error and so on. First, based upon kinematical analysis of a cutting machine, a mathematical description of tooth surface generation is given. Second, based upon the theory of gearing and differential geometry, conjugate tooth surfaces are studied. Then contact lines are generated. Third, load distribution along contact lines is formulated. Last, the numerical model is validated by measuring loaded transmission error and loaded tooth contact pattern.

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