Mathematic model and tooth contact analysis of a new spiral non-circular bevel gear

Abstract

A novel spiral non-circular bevel gear that could be applied to variable-speed driving in intersecting axes was proposed by combining the design principles of non-circular bevel gears and the manufacturing principles of face-milling spiral bevel gears. Unlike straight non-circular bevel gears, spiral non-circular bevel gears have numerous advantages, such as a high contact ratio, high intensity, good dynamic performance, and an adjustable contact region. In addition, while manufacturing straight non-circular bevel gears is difficult, spiral non-circular bevel gears can be efficiently and precisely fabricated with a 6-axis bevel gear cutting machine. First, the generating principles of spiral non-circular bevel gears were introduced. Next, a mathematical model, including a generating tooth profile, tooth spiral, pressure angle, and generated tooth profile for this gear type was established. Then the precision of the model was verified by a tooth contact analysis using FEA, and the contact patterns and stress distributions of the spiral non-circular bevel gears were investigated.

Keywords

non circular gear / spiral bevel gear / mathematic model / tooth contact analysis (TCA)

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