Computerized simulation of manufacturing errors in cylindrical spur gears and their compensation through flank modifications

Abstract

AGMA and ISO standards consider different types of deviation of gear geometry caused during manufacturing processes of cylindrical gears through a system of accuracy grades, in which each grade corresponds to deviations within a certain range. The gear drive behavior is affected by the level and type of deviation, causing transmission errors, shifts in the bearing contact, increase of contact and bending stresses, and vibration and noise. The main goal of this paper is the investigation of the influence of manufacturing errors on transmission errors and contact and bending stresses, and the determination of the corresponding flank modifications required for their compensation. The contact pattern and the unloaded function of transmission errors are obtained through application of tooth contact analysis (TCA). Application of finite element analysis (FEA) allows for contact and bending stresses to be determined along one or two cycles of meshing. Surface deformations are used for determination of the loaded function of transmission errors in which its peak-to-peak value is related to the vibration and noise response in operating conditions. Several numerical examples considering different levels and types of manufacturing error and their compensation through predefined flank modifications are presented.