Spiral bevel gears and hypoid gear pairs are used for motion and power transmission of vertical intersecting axes and spatial vertical intersecting axes respectively. They have the advantages of large coincidence, stable transmission, low noise and high bearing capacity. They are the main transmission components of high-precision, high-speed and heavy-duty facilities at present. Spiral bevel gears and hypoid gears are point contact meshing transmission, and the shape and position of the contact area can be adjusted by processing parameters. The transmission ratio of the calculation reference point changes slightly compared with that of other meshing points, but the fluctuation of the instantaneous transmission ratio is very small. Spiral bevel gears and hypoid gears can be divided into circular arc teeth and cycloid teeth according to the type of tooth line, which are called circular arc bevel gears and hypoid gears, Cycloid Bevel Gears and hypoid gears respectively. At present, there are mainly two systems in practical application: Oricon (Austrian system for short) and Klingenberg (restraint) long epicycloid equal height tooth system, which is processed and formed by continuous indexing method; Gleason (, referred to as “grid”) circular arc tooth system, which is processed and formed by single graduation method. Compared with circular arc bevel gear and hypoid gear, Cycloid Bevel Gear and hypoid gear adopt equal height teeth, which have longer spray line in the process of tooth meshing, so they have better stability and lower transmission noise. They are widely used in the main transmission of automobiles in developed countries abroad, but they have not been widely used in China, Only a few enterprises have introduced foreign processing equipment for trial production and small batch production, such as Hubei axle Co., Ltd. and Zhuzhou Gear Co., Ltd.
Because the tooth surface of Cycloid Bevel Gear and hypoid gear is a complex surface corresponding to the spiral motion relationship, it is generated by the spiral motion between the tool and the workpiece. At present, the most widely used machining method is cutting. However, Cycloid Bevel Gears and hypoid gears have low material utilization and high manufacturing cost due to complex parameter calculation and high technical content. When machining with machine tools, machining tools, machine parameters, loading deformation, assembly errors and other factors will cause changes in the whistled characteristics, bearing and vibration performance of gear pairs. It is difficult to control their quality and performance in the manufacturing process. At the same time, the continuity of metal fiber streamline will be cut off by cutting, As a result, the bending fatigue strength of the tooth root and the contact strength of the tooth surface are insufficient, and the bearing capacity of the gear decreases.
The precision forged Cycloid Bevel Gear and hypoid gear have dense structure, and the fiber streamline is continuous and evenly distributed along the tooth profile shape. They are superior to cutting processing in terms of gear strength, impact resistance, whistling noise and tooth surface wear resistance, and can reduce the cost, meeting the requirements of low carbon, high efficiency Precise sustainable development trend.
At present, the research on the precision forging of spiral bevel gears and hypoid gears at home and abroad mainly focuses on the driven wheel and driving wheel of arc bevel gears installed without offset.
Therefore, aiming at Cycloid Bevel Gear and hypoid gear, this paper studies the new machining method of small wheel based on plastic forming of large wheel, and puts forward a new semi generative machining method of Cycloid Bevel Gear and hypoid gear pair in which the small wheel adopts non generative cutting method to continuously index and mill the teeth, and the large wheel adopts precision forging, Compared with the current technology, it greatly improves the processing efficiency and has the advantages of reducing energy consumption and cost, so as to enhance the market competitiveness. The research work plays an important role in improving the manufacturing level of bevel gears and hypoid gears in China, lays a foundation for the diversification of gear products in China, and is of positive significance to the improvement of the quality of China’s equipment manufacturing industry and the development of the national economy.