In this study, an optimization methodology is proposed to systematically define the optimal head-cutter geometry and machine-tool settings to simultaneously minimize the tooth contact pressure and angular displacement error of the driven gear (the transmission error), and to reduce the sensitivity of face-hobbed spiral bevel gears to the misalignments. The proposed optimization procedure relies heavily on the loaded tooth contact analysis for the prediction of tooth contact pressure distribution and transmission errors influenced by the misalignments inherent in the gear pair. The load distribution and transmission error calculation method employed in this study were developed by the author of this paper. The targeted optimization problem is a nonlinear constrained optimization problem, belonging to the framework of nonlinear programming. In addition, the objective function and the constraints are not available analytically, but they are computable, i.e., they exist numerically through the loaded tooth contact analysis. For these reasons, a nonderivative method is selected to solve this particular optimization problem. That is the reason that the core algorithm of the proposed nonlinear programming procedure is based on a direct search method. The Hooke and Jeeves pattern search method is applied. The effectiveness of this optimization was demonstrated on a face-hobbed spiral bevel gear example. Drastic reductions in the maximum tooth contact pressure (62%) and in the transmission errors (70%) were obtained.
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August 2014
Research-Article
Optimal Machine-Tool Settings for the Manufacture of Face-Hobbed Spiral Bevel Gears
Vilmos V. Simon
Vilmos V. Simon
Department for Machine Design,
Faculty of Mechanical Engineering,
e-mail: simon.vilmos@gt3.bme.hu
Faculty of Mechanical Engineering,
Budapest University of Technology
and Economics
,H-1111 Budapest
,Műegyetem rkp. 3
, Hungary
e-mail: simon.vilmos@gt3.bme.hu
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Vilmos V. Simon
Department for Machine Design,
Faculty of Mechanical Engineering,
e-mail: simon.vilmos@gt3.bme.hu
Faculty of Mechanical Engineering,
Budapest University of Technology
and Economics
,H-1111 Budapest
,Műegyetem rkp. 3
, Hungary
e-mail: simon.vilmos@gt3.bme.hu
Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received March 19, 2013; final manuscript received May 1, 2014; published online June 2, 2014. Assoc. Editor: Zhang-Hua Fong.
J. Mech. Des. Aug 2014, 136(8): 081004 (8 pages)
Published Online: June 2, 2014
Article history
Received:
March 19, 2013
Revision Received:
May 1, 2014
Citation
Simon, V. V. (June 2, 2014). "Optimal Machine-Tool Settings for the Manufacture of Face-Hobbed Spiral Bevel Gears." ASME. J. Mech. Des. August 2014; 136(8): 081004. https://doi.org/10.1115/1.4027635
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