Digital modeling technology of spiral bevel gear

The spiral bevel gear calculation software is used to analyze the simulated contact mark. The calculated meshing area is compared with the actual meshing area to check the simulated coincidence degree, and then compared with the contact area required by the design, so as to obtain the parameters to be adjusted, repeatedly optimize this process, and finally obtain the qualified mark.

1. Spiral bevel gear modeling process

The digital modeling of spiral bevel gear is based on the calculation of the basic size of spiral bevel gear. The mathematical model of tooth surface is obtained by selecting the gear cutting method and inputting the basic geometric data.

Taking the spiral bevel gear pair of main reducer as an example, the digital modeling process of spiral bevel gear is described in detail. Carry out basic calculation according to the relevant dimensions of the design drawing. First, input the basic data of the pair of spiral bevel gears into the software according to the part drawing, such as shaft intersection angle, number of teeth, modulus, helix angle, rotation direction and pressure angle.

After inputting the basic data of the tooth, input the parameters of the tooth profile, such as tooth height modification coefficient, tooth thickness modification coefficient, tooth top height angle, tooth root height angle, average normal tooth thickness chord, large end full tooth height and large end tooth top height.

2. Simulation analysis of meshing marks of spiral bevel gears

The modification parameters such as helix angle error, pressure angle error, drum shape in tooth length direction, drum shape in tooth height direction and diagonal deformation in tooth length direction are continuously adjusted until the static impression meets the design requirements.

Input the power load of the gear pair for dynamic impression analysis until the dynamic meshing impression is adjusted to be qualified. The qualified dynamic impression is shown in Figure 1.

3. Spiral bevel gear machining process

The traditional spiral bevel gear processing adopts the five knife method. Firstly, the large wheel is processed, and then the concave and convex surfaces of the small wheel are adjusted and processed respectively. The static meshing mark is checked on the meshing machine. After repeated adjustment, the mark is qualified, and finally the large wheel and the small wheel are matched and handed over. However, this will lead to the non interchangeability of large and small wheels of different batches of parts. After repair, it may cause the risk of scrapping in pairs, resulting in huge cost waste. In order to solve the above problems, it is necessary to establish an electronic standard gear, so that the tooth surface profile before and after heat treatment is consistent, the grinding allowance is uniform after heat treatment, and the large and small wheels with inconsistent batches can also be exchanged, which not only saves the cost, but also improves the quality of parts. The machining process of spiral bevel gear tooth surface is shown in Figure 2.

(a) Gear milling (b) Gear grinding
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