University of Modena and Reggio Emilia

"Enzo Ferrari" Department of Engineering

Scuola di Dottorato in Ingegneria Industriale E Del Territorio

Tooth Profile Modification of

Straight and Spiral Bevel Gears

Under Supervision of:

Prof. Francesco Pellicano

Prepared by:
Farhad S. Samani 1 of 34
pur Gear

ical gear
Common
gears types

el gear

Worm gear
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 Vibration Excitation and Transmission Path (1)

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 Vibration Excitation and Transmission Path (2

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 Vibration Excitation and Transmission Path (3

5 5 of 34
 GEAR NOISE
Tavakoli & Houser, Optimum Profile Modifications for the Minimization of Static
Transmission Errors of Spur Gears, 1986.
e A procedure for computing static transmission errors and tooth load sharing was
developed.
Lin et al., Dynamic loading of spur gears with linear or parabolic tooth profile
modifications, 1994.
A computer simulation was conducted to investigate the effects of both linear and
parabolic tooth profile modification on the dynamic response of spur gears.
s Kahraman & Blankenship, "Effect of Involute Tip Relief on Dynamic Response of Spur
Gear Pairs“, 1999.
r The influence of gear tooth flank modifications in the form of linear involute tip relief on
the torsional vibration behavior of a spur gear pair is investigated experimentally.
r Chung et al., “Gear noise reduction through transmission error control and gear blank
dynamic tuning”, 1999.
n
A systematic approach to gear element design presented to optimize the gear blank
design from the perspective of the influence both the transmission error and system
dynamics on operating noise.
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 BEVEL GEAR VIBRATION
Nalluveettil & Muthuveerappan, "Finite element modelling and analysis of a straight bevel
e gear tooth“, 1993.
Finite element modeling and the analysis of a straight bevel gear is carried out. This paper
discusses the load distribution on the face of the tooth as well as the variation of load in
magnitude and position as the tooth rotates.
Elkholy & Elsharkawy, “Effect of Meshing Tooth Stiffness and Manufacturing Error on the
Analysis of Straight Bevel Gears”, 1998.
s A procedure for calculating transmitted load distribution along face width of straight beve
gears is introduced. The procedure is based upon the Tredgold assumption, which assume
r that a straight bevel gear can be approximated as a spur gear having a pitch radius equal to
the back-cone radius and same pitch as the bevel gear.
r Jian & Wan, "Nonlinear dynamic analysis for bevel-gear system under nonlinear
suspension-bifurcation and chaos", 2011.
n
The numerical results reveal that the system exhibits a diverse range of periodic, sub
harmonic, and chaotic behaviors. The results provide an understanding of the operating
conditions under which undesirable dynamic motion takes place.
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 SPIRAL BEVEL GEAR VIBRATION
e

Deng et al., “Analysis of meshing behavior and experiments of spiral bevel gears with
high contact ratio”, 2003.
A new approach to the gear geometric surface designed for increasing the contact ratio
They proposed to develop the design method for high contact ratio by means of sloping
the contact path. The designed gear set has lower transmission error.
s Artoni et al., “An ease-off based optimization of the loaded transmission error of hypoid
gears”, 2010.
r This study proposes a novel methodology to systematically define optimal topography to
simultaneously minimize Loaded transmission error (LTE) and contact pressures.
r Mu et al., “A novel tooth surface modification method for spiral bevel gears with higher
order transmission error”, 2018.
n
They present a novel method for designing high-contact-ratio spiral bevel gears with the
higher-order transmission error (HTE) based on the function-oriented design.

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 Dynamical model of a spur gear pair

9 9 of 34
 Manufacturing Error in a spur gear pair

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 Backlash Modeling

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 Transmission Error

12 12 of 34
 Profile Modifications
Tip and Root Relief

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 External Gear Design

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 Gear Model Output

15 15 of 34
 Gear Model Output

16 16 of 34
 OptiGear Software
A software for static and dynamic optimization of an external
gear pair
• Brute Force optimization method
• Random optimization method
s • Simplex method in optimization

r
• The meaning of static and dynamic optimization
• Peak to peak goal function
r

• Root mean square definition

n

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 SCHEMATIC OF BEVEL GEARS

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 TREDGOLD’S APROXIMATION

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 THE EQUATIONS OF MOTION

1 1 + 1 11 ( 11 1 − 21 2 − 1) + 2 12 ( 12 1 − 22 2 − 2) + 3 13 ( 13 1 − 23 2 − 3)
+ 1 11 ( 11 1 − 21 2 − 1) + 2 12 ( 12 1 − 22 2 − 2) + 3 13 ( 13 1 − 23 2 − 3) = 1

2 2 − 1 21 ( 11 1 − 21 2 − 1) − 2 22 ( 12 1 − 22 2 − 2) − 3 23 ( 13 1 − 23 2 − 3)
− 1 21 ( 11 1 − 21 2 − 1) − 2 22 ( 12 1 − 22 2 − 2) − 3 23 ( 13 1 − 23 2 − 3) =− 2

+ ( −e )+ () ( − )=
s
1

r = c1 11
2 + 2 12
2 + 3 13
2

= 1 11
2 + 2 12
2 + 3 13
2

1
r
2
=( + )
−1
n 1 2

− − − >
( − )= 0 − ≤ − ≤
− + − <−
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 Geometrical Data for case study
Parameters value
Number of teeth 32
Heel Module [mm] 6
Pressure angle 20∘
Face width [mm] 30
s
Module of elasticity [MPa] 206000

r
Poisson ratio 0.3
Pitch angle 45∘
r Outer cone normal backlash [mm] 0.1746

n Nominal torque [N mm] 317000

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 Design parameters of the artificial equivalent
spur gear pairs
Parameters First slice Second slice Third slice
Number of teeth 45 45 45
Module [mm] 5.7 5.3 4.8
Pressure angle [degree] 20 20 20
s Face width [mm] 10 10 10
Tip diameter [mm] 273.08 252.2 231.3
r Root diameter [mm] 247.08 228.2 209.3
Nominal torque [N mm] 125000 119000 103000
r

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 Static transmission error of the bevel gear slices

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 RMS value for three case studies

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 Bifurcation Diagrams

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 Bifurcation Diagrams

1.2

Nondimensional rms of oscillation

Nondimensional rms of oscillation

1.6
1.5 1.15
1.4
s 1.3 1.1
1.2
r
1.1 1.05

r 1
0.9 1
n 0 0.5 1 1.5 2
0 0.5 1 1.5 2 ωm/ωn
ωm/ ωn

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 PARAMETERS OF THE SPIRAL BEVEL GEAR
Parameters pinion gear
Cone angle 19.5o 70.5o
Number of teeth 23 65
Module [mm] 3.9
backlash [mm] 0.1
Nominal torque [N mm] 1000000
Module of elasticity [GPa] 206
Poisson ratio 0.3
s
Face width [mm] 37
Pressure angle 20°
r
Mean spiral angle 25°

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 MESH STIFFNESS OF PINION

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 RMS DIAGRAM

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 RMS diagram backward motion
• HTE • PTE

30 30 of 34
 RMS diagram forward motion
• HTE • PTE

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 1. The statically optimized tooth profile modifications for straight bevel gear is leads to declin
average value of dynamic transmission error 80%.
2. The dynamically optimized tooth profile modifications for straight bevel gear leads to de
the average value of dynamic transmission error (more than 97%).
3. There are some regions in involute tooth profile model that root mean square value of resp
s jump up or down depend on forward or backward motion. The maximum amplitude of jum
reduced noticeably for statically and dynamically optimized tooth profile, near 52% and
r
respectively.

r 4. It is observed that in straight bevel gears with optimized profile modifications, the p
doubling bifurcation regions are disappeared and their leftward-leaning behavior (soft
n
nonlinearity) decreased.

32 32 of 34
 5. For the investigated spiral bevel gears, the results show that the “higher-order transmissi
error” profile modification can improve the dynamic vibration particularly on the sup
harmonic resonances.
6. The “higher-order transmission error” method caused declining the average value of sta
transmission error to 35% as far as the pure involute teeth case is concerned for the investiga
spiral bevel gear. Though, it does not mean that minimizing the RMS of the dynam
transmission error occurred.
s
7. For spiral bevel gear there exist some regions in involute tooth profile model that root me
r square values of responses jump up or down based on the forward or backward motion. There
a noticeable reduction in the maximum amplitude of jumps for “higher-order transmissi
r
error”, near 44%. In addition to the primary resonance at ωm/ωn ≈ 1, two resonances
n
approximately ωm/ωn ≈ 1/2 and ωm/ωn ≈ 1/3 could be observed as super harmonics.

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