A comprehensive mesh stiffness model for heavy-duty spiral bevel gear pair based on design and manufacturing collaboration

Abstract

A comprehensive mesh stiffness model (CMSM) for heavy-duty spiral bevel gears (SBGs) was proposed based on design and manufacturing collaboration. First, a collaborative machining configuration model (CMCM) for face-milled SBGs was established based on the spread-blade cutting method (SBCM) and homogeneous coordinate transformation. Subsequently, an improved tooth contact analysis method (ITCAM) that included the unloaded transmission error (UTE) and contact characteristics was proposed with ease-off and elastic theory to compensate for program instability caused by the traditional tooth contact analysis method (TTCAM). Finally, a microsegment beam model containing teeth and a foundation was established using discrete means. The global flexibility matrix model (GFMM) was derived by combining the elastic potential energy principle and the nonlinear Hertz theory, which considers the axial flexibilities and coupling effects. Based on multitooth kinematics theory and the load conservation principle, a CMSM for design and manufacturing cooperation was developed. Using specific examples, the validity of CMSM was verified through comparison with the results of a numerical simulation, which showed that the proposed model can predict the mesh stiffness of SBGs with high accuracy under light or heavy loads.