Small module spiral bevel gears play an important role in industrial sewing machines, medical devices, robots, machine tools, military products and other industries, with large demand and broad development prospects. Small module spiral bevel gears are generally processed by double double side method, which belongs to the full process method. This method can reduce the number of gear clamping times, which is helpful to improve the cutting efficiency and gear accuracy, and reduce the processing cost. However, during the operation of the gear pair, the actual load fluctuates near the rated load. During the installation process, installation errors will inevitably be introduced. Due to the unique spatial transmission mode and complex tooth surface of spiral bevel gears, load fluctuations and installation errors will significantly affect the meshing performance of the gear pair, and further affect the overall performance of the whole machine, such as noise, transmission accuracy and service life. Therefore, it is of certain theoretical significance and engineering application value to study the influence of load and installation error on the meshing characteristics of double faced small module spiral bevel gears.
Many scholars at home and abroad have studied the design and meshing theory of double faced spiral bevel gears. KAWASAKI et al. used the arc cutting edge to process the big wheel by the forming method, and the small wheel used the linear cutting edge to ensure the local conjugate of the big and small wheels of the double double faced hypoid gear. Tang Jinyuan et al. developed a simulation system for the CNC machining of double sided spiral bevel gears on the CATIA platform to generate the three-dimensional solid model of the gear pair after machining. Zhang Hua et al. put forward a new method of small wheel double side milling and large wheel die forming for small module spiral bevel gears. Yang Jianjun et al. preset the meshing parameters of bilateral tooth surfaces and used nonlinear optimization to reverse calculate the machining parameters of the big wheel, taking the double double sided spiral bevel gear small wheel as a reference. Cui Bingyi and others used TCA to optimize the processing parameters of double sided small module spiral bevel gears and improve the tooth surface contact. Jiang Yabo designed the big wheel parameters and carried out powder metallurgy on the basis of double side generating processing of spiral bevel gear small wheels. Hu Xinfang proposed the machining method of the dual side tooth surface of the pre control gear based on the spiral bevel gear small wheel machined by the dual side method, and carried out the tooth cutting experiment to verify it. Zhang Weiqing and others put forward the method of double rolling small module spiral bevel gear, and developed CNC software to realize automatic tool setting. The above work is mainly based on the exploration of new machining methods of double double faced spiral bevel gears and the optimization analysis of gear parameters by TCA method.
Loading contact analysis (LTCA) is an important method of gear design and evaluation nowadays, which simulates the meshing state of gear pair under loading deformation through computer, and more truly reflects the state of gear pair in the loading process. Hou Xiangying et al. established a finite element model considering the edge contact for spiral bevel gears, and discussed the influence of load on the edge contact of gear pairs. Su Jinjin and others put forward
The design method of spiral bevel gear with large contact degree along the tooth length direction of the mesh mark is used to design the tooth surface of the small gear, and then the processing parameters of the small gear are reverse calculated. Jiang Jinke et al. aimed to minimize the amplitude of load transmission error, flash temperature of tooth surface and maximize the average meshing efficiency, and carried out multi-objective optimization based on ease off hypoid gears. Yan Hongzhi and others used arc cutter to process spiral bevel gear based on double helix method, which can reduce the sensitivity of tooth surface installation error. FU et al. based on the spiral bevel gear of a heavy vehicle, explored the influence of load on the bending stress of tooth root, contact stress of tooth surface and transmission error, and verified it through experiments. PENG et al. proposed the LTCA method for spiral bevel gears considering the time-varying meshing characteristics, and determined the contact pressure and stress distribution under elliptical loading for instantaneous and whole tooth contact respectively. LIU et al. established a model considering fixture error based on the surface rolling hypoid gear trihedral milling cutter, and separated the long wave and short wave of transmission error from the total transmission error. YANG et al. discussed the influence of the installation error on the meshing characteristics of the hypoid gear for automobile rear deck rolling. LIANG et al. analyzed the influence of straight line, circular arc and polynomial tool sections on tooth surface deviation and meshing characteristics. The results showed that polynomial tool can reduce transmission error without increasing tooth root bending stress.
The LTCA method is used to analyze the meshing characteristics of gear pairs, but the LTCA research on small module spiral bevel gears is less. Therefore, on the basis of establishing the mathematical model of double double faced small module spiral bevel gear, LTCA method is adopted to analyze the meshing characteristics of gear pair under rated load, discuss the influence of load on the meshing characteristics of gear pair, and explore the influence of axial installation error of small wheel, axial installation error of large wheel and axial intersection angle installation error on the meshing characteristics of gear pair.