Power density and efficiency have always been the main goals pursued in the field of mechanical transmission, among which gear transmission with few teeth is one of the important means to achieve this goal. High reduction hypoid gear (HRH) has the advantages of high degree of engagement, small number of teeth, light weight and high efficiency. It has broad application prospects in the field of electromechanical highly integrated power transmission. A spiral bevel gear with three teeth is designed by using the principle of “non-zero displacement”. The geometric evolution law of HRH gear is studied through meshing simulation, and the HRH gear with one tooth is studied. These studies have laid a certain foundation for the meshing theory and engineering test of HRH gear. However, the machining calculation and meshing quality control of HRH gear have always been difficult problems in the industry, especially when the HRH gear can not be machined by the conventional tool tilt method (HFT) or the hypoid generating modified method (HGM), it is extremely difficult to correct the curvature of its tooth surface.
Aiming at the problem of tooth profile error correction of spiral bevel gears, a mathematical model of inverse adjustment optimization is established, so that the tooth cutting adjustment parameters of bevel gears can be obtained more accurately. By introducing the concept of digital synthetic error, a digital real tooth surface model of spiral bevel gear with tooth profile error and installation error is established, and a high-precision digital real tooth surface contact analysis method of spiral bevel gear is given. The principle of converting the machining parameters of mechanical gear milling machine into the motion parameters of CNC gear grinding machine is studied, and the corresponding conversion expression is given. The method of measuring and compensating the tooth profile error is further studied.
Based on the principle of high-order universal motion of machine coordinates, a method of modifying the high-order errors of tooth surfaces is given. A method of tooth surface machining and error correction directly facing the 6-axis CNC machine tool is given, and the high-order correction of the tooth surface can be completed through the high-order control of the moving shaft. With the help of the tooth load contact analysis and the ease off diagram of the tooth surface relative modification, the spiral bevel gear with the fourth-order transmission error is compared and analyzed. Based on the ease off surface topology principle, the tooth surface correction method for high-order transmission errors of spiral bevel gears is presented. These studies have laid a good theoretical and technical foundation for the lean design of complex spiral bevel gear tooth surface. However, most of the above methods are limited to the “local synthesis” of the second-order surface in the neighborhood of the reference point, facing the highly twisted HRH tooth surface, and it is difficult to control the topology of the tooth surface far from the neighborhood.
In view of this, the surface synthesis method is proposed to control the accuracy of the topological modification of the tooth surface through the synthesis of the whole tooth surface. Based on this, this paper will synthesize the method of surface analysis and tool modification to solve the problem of the height torsion and curvature correction of the HRH tooth surface, establish the relevant machining calculation simulation model, and finally carry out the meshing quality inspection and dynamic performance test.