Chapter 7

Interactive Control of the Teeth Gear

Shaping in the Cutting Tools Design

Borys S. Vorontsov, Vitalii A. Pasichnyk, and Yuliia V. Lashyna

7.1 Introduction

Interactive control of the gearing and tool design process can be effectively carried
out using unified control parameters that change not only the shape of the initial
surface of the teeth, but simultaneously all the elements of the system, including the
geometric and kinematic indicators of the gearing process.

7.2 Bezier Curves

It is possible to reduce the existing mathematical descriptions of curves used in

existing descriptions of coordinate lines of surfaces to a single form by using spline
curves. Bezier curves [1] take a special place in the tasks of controlling the shape of
lines. In addition, they have found applications in most of the existing solid and
surface modeling CAD systems.
Several four-point Bezier polygons and the resulting cubic curves are shown in
Fig. 7.1.
The first and last points on the curve are coincident with the first and last points of
the defining polygon.
The tangent vectors at the ends of the curve have the same direction as the first
and last polygon spans, respectively.
The curve is contained within the convex hull of the defining polygon, i.e., within
the largest convex polygon defined by the polygon vertices.

B. S. Vorontsov (*) · V. A. Pasichnyk · Y. V. Lashyna

National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”,
Kyiv, Ukraine

© The Author(s), under exclusive license to Springer Nature Switzerland AG 2022 205
S. P. Radzevich, M. Storchak (eds.), Advances in Gear Theory and Gear Cutting
Tool Design, https://doi.org/10.1007/978-3-030-92262-7_7
206 B. S. Vorontsov et al.

Fig. 7.1 Bezier polygons for cubics. (After: Rodgers and Adams [4])

With just the information given above, a user quickly learns to predict the shape
of a curve generated by a Bezier polygon.

7.3 Generating Surface

Figure 7.2 shows the profile of the generating surface. The third-order Bezier curve
[3] is shown as a curve that allows modifying the profile during the interactive
synthesis.
Third-order Bezier curve equation [3]:

Pðt Þ ¼ B0 J 3,0 þ B1 J 3,1 þ B2 J 3,2 þ B3 J 3,3

¼ ð1  t Þ3 P0 þ 3t ð1  t Þ2 P1 þ 3t 2 ð1  t ÞP2 þ t 3 P3

We represent it in the following form:

r к ðλÞ ¼ ð1  λÞ3 P0 þ 3ð1  λÞ2 λP1 þ 3ð1  λÞλ2 P2 þ λ3 P3 , ð7:1Þ

or in the parametric form:

7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 207

Fig. 7.2 Generating surface

profile: (а) standard and (b)
modified

xк ¼ f 1 ðλ, Px Þ ¼ ð1  λÞ3 x0 þ 3ð1  λÞ2 λx1 þ 3ð1  λÞλ2 x2 þ λ3 x3 ,

 ð7:2Þ
yк ¼ f 2 λ, Py ¼ ð1  λÞ3 y0 þ 3ð1  λÞ2 λy1 þ 3ð1  λÞλ2 y2 þ λ3 y3 ,

where:
Px ¼ (x0, x1, x2, x3) and Py ¼ (y0, y1, y2, y3) are the radius vectors of coordinates of the
control points Р0, Р1, Р2, Р3
λ ¼ 0...1 is the current parameter that defines a point on the curve.
The pressure angle is determined from the expression:

f 1 0 ðλ, Px Þ
tgαп ¼
, ð7:3Þ
f 2 0 λ, Py

where:

f 1 0 ðλ, Px Þ ¼ 3ðx0 þ 3x1  3x2 þ x3 Þλ2 þ 6ðx0  2x1 þ x2 Þλ þ 3ðx1  x0 Þ,

f 1 0 ðλ, Px Þ ¼ 3ðy0 þ 3y1  3y2 þ y3 Þλ2 þ 6ðy0  2y1 þ y2 Þλ þ 3ðy1  y0 Þ
ð7:4Þ

are the first derivatives of functions f1(λ, Px) and f2(λ, Py) with respect to λ.
When analyzing the geometry and deriving formulas for determining geometric
and kinematic indicators, it is necessary to know the second derivatives, which have
the form:

f 1 00 ðλ, Px Þ ¼ 6ðx0 þ 3x1  3x2 þ x3 Þλ þ 6ðx0  2x1 þ x2 Þ,

 ð7:5Þ
f 2 00 λ, Py ¼ 6ðy0 þ 3y1  3y2 þ y3 Þλ þ 6ðy0  2y1 þ y2 Þ:

To obtain the equation of the generating surface with control parameters, we

introduce the coordinate system S1 (see Fig. 7.3).
208 B. S. Vorontsov et al.

Fig. 7.3 Generating surface

Plane Y1O1Z1 coincides with the starting plane of the guide. Let a spatial curve be
specified in the X1Y1Z1 coordinate system, which determines the longitudinal shape
of the created surface. The general equation of this curve is as follows:

r 0 ðμ, N Þ ¼ x0 ðμ, N Þ i þ y0 ðμ, N Þ j þ z0 ðμ, N Þ k ð7:6Þ

where:
x0(μ, N ) , y0(μ, N ) , z0(μ, N ) – are arbitrary functions differentiable with respect to
the argument the required number of times.
If the guide is described by a third-order Bezier curve, then

r 0 ðμ, N Þ ¼ f N ðμÞ ¼ ð1  μÞ3 n0 þ 3ð1  μÞ2 μ  n1 þ 3ð1  μÞ  μ2 n2 þ μ3 n3 ð7:7Þ

where:
n0 ¼ (y0, z0), n3 ¼ (y3, z3) are the radius vectors of the coordinates of the control
endpoints.
n1 ¼ (y1, z1), n2 ¼ (y2, z2) are the radius vectors of the coordinates of the intermediate
control points.
μ ¼ 0...1 is the current parameter that defines a point on the curve.
Equation for the interactively controlled surface in the coordinate system S1 is
represented as follows:

r 1 ðλ, μÞ ¼ f 1 ðP, N Þ,

where P¼P ( p0, p1, p2, p3) and N ¼ N (n0, n1, n2, n3) are the vectors of control points
from Eqs. (7.2) and (7.7).
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 209

We place the origin of the coordinate system Sк on the curve (7.6). In this case, the
OкXк axis is directed along the binormal, OкYк along the principal normal, and OкZк
is tangential to this curve. The plane parallel to the X1O1Y1 plane will be called the
transverse plane of the generating surface, and the section of the generating surface
by this plane will be called the transverse section. The section of the generating
surface by the plane XкOкYк will be called the normal section.
Equation of the generating surface in the coordinate system Sn:


r n ðλ, μ, P, N Þ ¼ r 0 ðμ, N Þ þ bn ðμ, N Þ f 1 ðλ, Px Þ þ nn ðμ, N Þ f 2 λ, Pу , ð7:8Þ

or in the parametric form


xn ðλ, μ, P, N Þ ¼ xn ðμ, N Þ þ bxn ðμ, N Þ f 1 ðλ, Pх Þ þ nxn ðμ, N Þ f 2 λ, Pу


yn ðλ, μ, P, N Þ ¼ yn ðμ, N Þ þ byn ðμ, N Þ f 1 ðλ, Pх Þ þ nyn ðμ, N Þ f 2 λ, Pу ; ð7:9Þ


zn ðλ, μ, P, N Þ ¼ zn ðμ, N Þ þ bzn ðμ, N Þ f 1 ðλ, Pх Þ þ nzn ðμ, N Þ f 2 λ, Pу ,

where:
bxn(μ, N ), byn(μ, N ), bzn(μ, N ) are the direction cosines of binormals.
nxn(μ, N ), nyn(μ, N ), nzn(μ, N ) are the direction cosines of the principal normal.
A tooth surface of the generating gear can act as the generating surface. For a
spline profile, the equation of the generating spur gear, considering expressions (7.2)
in the moving coordinate system S1(x1y1z1), will have the form:


x1 ¼ f 1 ðλ, Px Þ  r 1 ; y1 ¼ f 2 λ, Py ; z1 ¼ μ ð7:10Þ

In the vector form, the equation of a spur gear with any profile can be represented
as follows:

! !
! !
r 1 ðλ, μ, P, N Þ ¼ ½ f 1 ðλ, Px Þ  r 1  i þ f 2 λ, Py j þ μ k ð7:11Þ

When studying the geometry of complex surfaces, as well as in order to obtain

geometric and kinematic indicators of contacting surfaces in the processes of
generating the shape and operation, the following elements of a complex surface
are required: the normal and its projections on the coordinate axes; coefficients of the
first and second quadratic forms; and normal curvatures in given directions.
The normal vector is defined by the formula [3]:

N n ¼ r λn  r μn , ð7:12Þ

where r λn and r μn are partial derivatives of the radius vector of the generating surface
(7.8) with respect to λ and μ accordingly:
210 B. S. Vorontsov et al.




r μn ¼ jr n 0 j  1  Kf 2 λ, Pу  sin βj þ cos βk ;


 ð7:13Þ
r λn ¼ f 01 ðλ, Pх Þi þ f 02 λ, Pу cos βj  f 02 λ, Pу sin βk,

where:


f 01 ðλ, Pх Þ and f 02 λ, Pу are the derivatives of functions f1(λ, Pх) and f2(λ, Pу) with
respect to λ (7.4).
qffiffiffiffiffiffiffiffiffiffiffiffiffiffi
jr n 0 j ¼ y_ 2n þ z_ 2n is the modulus of the derivative of the radius vector of the curve
(7.6).
K ¼  €z02y_ 0 €y20 z_ 03=2 is the curvature of the curve (7.6).
ðy_ 0 þ_z0 Þ
Substituting (7.13) into (7.9), we obtain the projections of the normal vector to the
generating surface:
 


N xn ¼ r 0n   1  Kf 2 λ, Pу  f 02 ðλ, PуÞ;
 0


N yn ¼ r n   1  Kf 2 λ, Pу  f 01 ðλ, Pх Þ cos β; ð7:14Þ
 0


N zn ¼ r n   1  Kf 2 λ, Pу  f 01 ðλ, Pх Þ sin β:

Due to the fact that the modulus of the normal vector is equal to:

   0

 qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2

2ffi
N n  ¼ r   1  K f 2 λ, Pу  f ðλ, Pх Þ þ f 0 λ, Pу , ð7:15Þ
n 1 2

the unit normal vector in the parametric form can be represented as:


f 2 0 λ, Pу
exn ¼  q
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2

2ffi ;
f 01 ðλ, Px Þ þ f 02 λ, Pу
f 01 ðλ, Pх Þ cos β
eyn ¼ q
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2

2ffi ; ð7:16Þ
f 01 ðλ, Pх Þ þ f 02 λ, Py
f 01 ðλ, Pх Þ sin β
ezn ¼  qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2

2ffi ,
f 1 ðλ, Pх Þ þ f 02 λ, Py

or,

exn ¼  sin α; eyn ¼ cos α cos β; ezn ¼  cos α sin β ð7:17Þ

In the general case, the coefficients of the first quadratic form are as follows [3]:
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 211

2
2
2
2
En ¼ xλn þ yλn þ zλn ¼ r λn ;
F n ¼ xλn xμn þ yλn yμn þ zλn zμn ¼ r λn r μn ; ð7:18Þ

2
Gn ¼ r μn

For the surface (7.9), considering (7.13), we obtain:

 2 
2
E n ¼ f 01 ðλ, Pх Þ þ f 02 λ, Pу ;
F n ¼ 0; ð7:19Þ
 2

2
2 

2
Gn ¼ r 0   1  Kf 2 λ, Pу
0 ¼ y_ þ z_ 2  1  Kf 2 λ, Pу
n n

Coefficients of the second quadratic form [3] are as follows:

2 2 2 2
∂ xn ∂ yn ∂ zn ∂ rn
Ln ¼ exn þ e yn þ e zn ¼ e n ;
∂λ2 ∂λ2 ∂λ2 ∂λ2
2 2 2 2
∂ xn ∂ yn ∂ zn ∂ rn
M n ¼ exn þ eyn þ ezn ¼ en ; ð7:20Þ
∂λ∂μ ∂λ∂μ ∂λ∂μ ∂λ∂μ
2 2 2 2
∂ xn ∂ yn ∂ zn ∂ rn
N n ¼ exn þ e yn þ e zn ¼ e n ,
∂μ2 ∂μ2 ∂μ2 ∂μ2

The second derivatives of the radius vector of the generating surface with respect
to λ and μ:

∂ rn
2


¼ f 001 ðλ, Pх Þi þ f 002 λ, Py cos βj  f 002 λ, Py sin βk ð7:21Þ
∂λ 2

2
∂ rn


¼ K f 02 λ, Pу  y_ n j þ z_ n k ð7:22Þ
∂λ∂μ

∂ rn
2 



¼ €yn 1  Kf 2 λ, Pу  K 0 y_ n f 2 λ, Pу  jþ
∂μ2 


 ð7:23Þ
þ €zn 1  Kf 2 λ, Pу  K 0 z_ n f 2 λ, Pу  k;


where f 001 ðλ, Pх Þ and f 002 λ, Pу are the second derivatives of functions f1(λ, Pх)and
f2(λ, Pу) with respect to λ (7.5).
Substituting (7.21), (7.22), and (7.23) in (7.20), we obtain the dependences for
determining the coefficients of the second quadratic form:
212 B. S. Vorontsov et al.


Ln ¼  f 001 ðλ, Pх Þ sin α þ f 002 λ, Pу cos α;
M n ¼ 0; ð7:24Þ

 

N n ¼ K cos α  y_ 2n þ z_ 2n  1  Kf 2 λ, Pу :

Relations (7.19) and (7.24) depend on the functions that determine the original
contour and the longitudinal shape of the teeth of the generating surface. They are
generalized and apply to general gear racks.
The normal curvature of the generating surface in general can be determined by
the dependence [3]:

Ln dλ2 þ 2M n dλdμ þ N n dμ2

K¼ , ð7:25Þ
En dλ2 þ 2F n dλdμ þ Gn dμ2

where dλ and dμ are the differentials of coordinate lines λ and μ.

The direction in which the curvature is determined depends on the values dλ and
dμ. Thus, for instance, the curvature along the lines λ ¼ const, (dλ ¼ 0) (Fig. 7.3) is
equal to:

Nn K cos α
Kμ ¼ ¼
, ð7:26Þ
Gn 1  K f 2 λ, Py

and the curvature along the lines μ ¼ const, i.e., profile curvature (Fig. 7.2), is
equal to:



Ln f 01 ðλ, Pх Þ f 002 λ, Py  f 001 ðλ, Pх Þ f 02 λ, Py
Kλ ¼ ¼ h
: ð7:27Þ
En 2

2 i32
f 01 ðλ, Pх Þ þ f 02 λ, Py

Since for the considered generating surface, the coefficients of the quadratic
forms are Fn ¼ 0 and Mn ¼ 0, coordinate lines λ ¼ const and μ ¼ const are the
lines of curvature, and the normal curvatures Kμ and Kλ are the principal curvatures
of the surface (7.9).

7.4 Gear Geometry

Coordinate systems of the kinematic schemes for shape generation are shown in
Fig. 7.4.
S1 – coordinate system associated with the driving gear (pinion)
S2 – coordinate system associated with the driven gear
S – fixed coordinate system
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 213

Fig. 7.4 Coordinate

systems

The starting cylinder of the workpiece rolls over the starting plane of the
generating surface. Plane YnOnZn is the starting plane of the rack and the YOZ
plane coincides with the plane YnOnZn, while the OZ axis coincides with the pole
line. OY axis coincides with the axis OnYn. Plane YOX passes through the middle
transverse section of the gear. Axes O1Z1 and O2Z2 are the axes of rotation of cut
gears. These axes are parallel to the axis OZ. R1 and R2 are the radii of the initial
cylinders and φ1 and φ2 are angles of rotation of a pinion and a gear. Hereafter, the
index “1” will denote the elements that refer to the pinion, and the index “2” will
denote the elements that refer to the gear. When the workpiece is rotated through the
angle φI, the generating surface moves by an amount Riφi.
The transition from one coordinate system to another will be carried out by the
matrix method.
Matrix representation of the kinematic scheme for the shape generation:

r 2 ðλ, μ, P, N Þ ¼ M62p ðϕ2 Þ  M1pl ðR1 þ R2 Þ  M4lm ð0Þ  M3mk ð0Þ  M6k1 ðϕ1 Þ
  r 1 ðλ, μ, P, N Þ

! ! ð12Þ
The generating relationship [3, 5] n 1 V 1 ¼ 0 and the functional relationship
u ¼ ω2/ω1 remain unchanged.
Hereafter, we will need the following transformation matrices [3]:
• The matrix for transition from the coordinate system Sn to S will have the form
[3]:
214 B. S. Vorontsov et al.

 
1 0 0 0 
 
0 0 Ri ϕi 
 1 
M 0n ¼ ; ð7:28Þ
0 0 1 0 
 
0 0 0 1 

• The matrix for transition from the coordinate system S to Si [3]:

 
 cos ϕi  sin ϕi 0 Ri cos ϕi 
 
  sin ϕ cos ϕi Ri sin ϕi 
 i 0 
M i0 ¼  ; ð7:29Þ
 0 0 1 0 
 
 0 0 0 1 

• The matrix for transition from the coordinate system Sn to Si [3]:

 
 cos ϕi  sin ϕi 0 Ri ð cos ϕi þ ϕi sin ϕi Þ 
 
  sin ϕ cos ϕi Ri ð sin ϕi  ϕi cos ϕi Þ 
 i 0 
M in ¼  ; ð7:30Þ
 0 0 1 0 
 
 0 0 0 1 

• The inverse matrix for transition from the coordinate system Si to Sn [3]:

 
 cos ϕi  sin ϕi 0 Ri 
 
  sin ϕ cos ϕi Ri ϕi 
 i 0 
M ni ¼  : ð7:31Þ
 0 0 1 0 
 
 0 0 0 1 

We also need the derivative of the matrix (7.30) with respect to the parameter ϕi
[3]:
 
  sin ϕi  cos ϕi 0 Ri ϕi cos ϕi 
 
 Ri ϕi sin ϕi 
dM in   cos ϕi  sin ϕi 0 
¼ : ð7:32Þ
dϕi  0 0 1 0 
 
 0 0 0 1 

Here, i ¼ 1 for the pinion, i ¼ 2 for the gear; the upper sign corresponds to the
pinion and the lower sign to the gear.
The matrix for transition from the coordinate system S1 to S2 can be represented
as follows [3]
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 215

 
 cos ðϕ1 þ ϕ2 Þ  sin ðϕ1 þ ϕ2 Þ 0 ðR1 þ R2 Þ cos ϕ2 
 
 sin ðϕ þ ϕ Þ cos ðϕ1 þ ϕ2 Þ ðR1 þ R2 Þ sin ϕ2 
 1 2 0 
M 21 ¼ : ð7:33Þ
 0 0 1 0 
 
 0 0 0 1 

Matrix representation of the first type of the kinematic scheme for the shape
generation of the 2nd class:

r i ðλ, μ, P, N Þ ¼ M6is ðϕi Þ  M1s0 ðRi Þ  M20n ðyn Þ  r n ðλ, μ, P, N Þ

The functional relationship:

yn ¼ R i  ϕi

Applying the matrix (7.28) to transform the coordinates of the surface (7.10), we
obtain the equation of the generating surface in the fixed coordinate system S as
follows:

x ¼ f 1 ðλ, Pх Þ;


y ¼ yn ðμ, N Þ þ f 2 λ, Pу cos β  Ri ϕi ; ð7:34Þ


z ¼ zn ðμ, N Þ  f 2 λ, Pу sin β:

The function of shaping a complex surface using a tool surface is: [3]

ni
F i ¼ V  en ¼ 0, ð7:35Þ

where:
en is the unit normal vector (7.17).
ni
V is the relative velocity in the cutter tool surface meshing with the cut wheel [3]:

ni dM in
V ¼ M ni r ð7:36Þ
dϕi n

Considering (7.31), (7.32) and (7.11) we obtain:

ni 
 
V ¼ yn ðμ, N Þ  f 2 λ, Pу cos β  Ri ϕi  i  f 1 ðλ, Pх Þ  j ð7:37Þ

To obtain the actual value of the relative velocity, it is necessary to multiply the
right side of expression (7.37) by the angular velocity ωi.
Substituting the values (7.17) and (7.37) into (7.35), we obtain the equation of the
shape generation function in the form:
216 B. S. Vorontsov et al.

F i ðλ, μ, P, N Þ ¼ ½yn ðμÞ  Ω2 ðλ, μ, P, N Þ  cos β  Ri ϕi   sin α ¼ 0 ð7:38Þ

where:

 f ðλ, Pх Þ  f 01 ðλ, Pх Þ
Ω2 ¼ Ω1 þ f 2 λ, Pу ; Ω1 ¼ 1
 :
f 02 λ, Pу

Equation (7.34) together with (7.38) determines the surface of cutter tool
meshing, i.e., locus of points at which contact between the tool surface and the
machined surface occurs. By eliminating one of the parameters from these equations,
for instance ϕi, we obtain the equation of the cutter tool meshing surface in a
parametric form:

x ¼ f 1 ðλ, Pх Þ;
y ¼ Ω1 cos β; ð7:39Þ


z ¼ zn ðμ, N Þ  f 2 λ, Pу sin β:

When using the same generating surface for cutting the pinion and the gear, we
will have the case of the linear contact in the working gearing. For gears that were cut
without tool offset, the tool meshing surface coincides with the surface of the
working engagement of the gears.
When z ¼ const, the Eq. (7.39) determines the tool meshing line in the transverse
plane. For gears with linear contact, this tool meshing line will be the path of contact
of working gearing in the transverse plane. For gears with the point contact, the line
of engagement in the transverse plane degenerates into a point.
When ϕi ¼ const, Eqs. (7.34) and (7.38) determine the line of instant contact
(characteristic) of the generating surface and the surfaces of the cut gears teeth. For
gears, which were cut without tool offset, this line coincides with the line of instant
contact of the meshing gears teeth.
The relative velocity in the cutter tool meshing considering (7.37) and (7.38) is
determined for ωi ¼ 1 according to the formula:

ni
V ¼ Ω1 cos βi  f 1 ðλ, Pх Þj ð7:40Þ

7.5 Parameters of Teeth Surfaces of Cut Gears

To determine the equations of teeth surfaces of cut gears, it is necessary to present

the equations of the cutting tool meshing surface in coordinate systems S1 or S2. To
do this, we use the transformation matrix (7.29). The equations of the contacting
teeth surfaces in the coordinate system Sі have the form:
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 217

xi ¼ ½ f 1 ðλ, Pх Þ  Ri  cos ϕi  Ω1 cos β sin ϕi ;

yi ¼ ½Ri  f 1 ðλ, Pх Þ sin ϕi  Ω1 cos β cos ϕi ; ð7:41Þ


z ¼ zn ðμ, N Þ  f 2 λ, Pу sin β:

Equations (7.41) allow determining the thickness of the teeth for bending calcu-
lations, as well as the control dimensions of the cut gears.
At ϕi ¼ const, Eqs. (7.41) are the equations of instant contact lines of meshing
gears. At z ¼ const, these equations describe the profiles of the pinion and gear teeth
in the transverse section, and at β ¼ const, they describe the tooth profiles in the
normal section.
At λ ¼ const, Eqs. (7.41) represent the equations of helical lines. The radii of the
pffiffiffiffiffiffiffiffiffiffiffiffiffiffi on which these lines are located can be determined by the formula Rbi ¼
cylinders
x2i þ y2i or, considering (7.41):
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Rbi ¼ ½ f 1 ðλ, Px Þ  Ri 2 þ ðΩ1 cos βÞ2 , ð7:42Þ

where the upper sign is for the pinion and the lower one is for the gear.
Since in the general case β is variable, then at λ ¼ const, Rb1 and Rb2 vary along
the gear ring.
Equations (7.42) can be used to determine the corresponding boundary points of
the gear engagement field. To do this, in the right parts of the relation (7.42), it is
necessary to substitute the values of Rа1 and Ra2 which are the radii of the tip circles
of the pinion and the gear, respectively, and solve them with respect to λ. The
obtained values of λ allow to define some indicators of gears efficiency.
To determine the teeth thickness in the transverse section, it is necessary to set the
value of zi and determine μ(λ) from the last Eq. (7.42). Then, given Rb1 and Rb2,
determine λ1 and λ2 from the Eq. (7.42) and the angle ϕi from the equation of
meshing (7.38).
Substituting the obtained μ, λ, ϕ into the first two Eqs. (7.41), we find the
coordinates of the tooth profile in the transverse section for the given Rb1 and Rb2.
For a symmetrical initial contour, the thickness of the cut gear tooth in the
transverse section is

S ¼ 2  jyi j ¼ 2  j½Ri  f 1 ðλ, Pх Þ sin ϕi  Ω1 cos β cos ϕi j ð7:43Þ

The distance from the tooth top to the measuring chord (measuring height) is
h  ¼ Rai  xi, where xi is determined from the first Eq. (7.41).
For an asymmetric original contour, it is necessary to determine the positive and
negative yi values and, to obtain S, sum the absolute yi values.
When determining the thickness of the teeth, it is necessary to take Rai instead of
Rbi in the relations (7.42).
218 B. S. Vorontsov et al.

7.6 Interactive Control of the Shaping Process

for Kinematic Shape Generating Schemes of the 2nd
Class

The aforementioned mathematical dependencies formed the basis for the software
“SAlAT” [2]. The software is developed for integrated parametric modeling of
systems and processes for shaping complex surfaces.
Software interface (Fig. 7.5) allows controlling the following objects by using the
cursor:
• The geometry of the original contour of the generating surface
• The shape of the working sections of the curves describing pinion and gear teeth
in the normal section
• The shape of the path of contact, which is the locus of the contact points for the
pinion, the wheel, and the generating surface of the rack-and-pinion type in a
given section.
Figure 7.6 shows a print screen with the corresponding explanations. When
changing the curve of the original contour of the generating surface 1 using the
control points 4 of the Bezier curve, there is a change in the curves describing the
working area of the pinion and the gear teeth.

Fig. 7.5 Controlling the resulting objects

7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 219

Fig. 7.6 Control of the working areas of the teeth: 1 – the curve of the original contour of the
generating surface; 2 – the curve describing the working area of the pinion tooth; 3 – the curve
describing the working area of the gear tooth; 4 – control points of the Bezier curve

Similarly, in Fig. 7.7, it can be observed how the path of contact changes due to
changing the curve of the original contour of the generating surface using the control
points of the Bezier curve.
Figure 7.8 shows three positions of the curves obtained during the process of
generating the pinion, the wheel, and the generating surface.

7.7 Geometric and Kinematic Parameters of Gears

and Their Visual Analysis

Geometric and kinematic parameters of gears are analyzed using the software
«SAlAT» [2], designed for integrated parametric modeling of systems and processes
for shaping complex surfaces. Figure 7.9 shows a visual analysis of geometric and
kinematic indicators of contacting surfaces for kinematic shape generation schemes
of the 2nd class.
By changing the geometry of surfaces with the help of control elements, it is
possible to simultaneously visually analyze the change in geometric and kinematic
indicators at the point of surfaces contact and compare their values with the
original ones.
220 B. S. Vorontsov et al.

Fig. 7.7 Control of the path of contact

Fig. 7.8 Analysis of the objects’ interaction in the generating process

7.7.1 Relative Sliding Velocity of Working Srfaces

The relative sliding velocity is one of the indicators of the intensity and nature of
wear on the working surfaces of teeth.
In the working gearing, the relative velocity is equal to [3, 5]:

12 1 2
V ¼ Vr  Vr ð7:44Þ

ð1Þ ð2Þ
where V r , V r are the velocity vectors of the point of contact when moving,
respectively, on the surface of the pinion and the gear, which can be determined
from the equation:
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 221

Fig. 7.9 Visual analysis of geometric and kinematic indicators

ðiÞ ðnÞ ðniÞ

Vr ¼ V þV ð7:45Þ

ð nÞ
Here, V is the velocity vector of the contact point when moving along the
ðniÞ
generating surface and V is the vector of the relative velocity at the engagement of
the generating surface with the cut wheel.
Substituting (7.45) into (7.44) we obtain:

ð12Þ ðn1Þ ðn2Þ

V ¼V V ð7:46Þ

or considering (7.40),

ð12Þ  
V ¼ ðω1 þ ω2 Þ Ω1 cos βi þ f ðλ, Px Þj , ð7:47Þ

where, ω1, ω2 are the angular velocities of the pinion and the gear, respectively.
In a fixed XYZ coordinate system, the projection of the relative velocity vector can
be represented as follows:
222 B. S. Vorontsov et al.

V ðx12Þ ¼ ðω1 þ ω2 ÞΩ1 cos β;

V ðy12Þ ¼ ðω1 þ ω2 Þ f 1 ðλ, Px Þ; ð7:48Þ
ð12Þ
VΖ ¼0

Consequently, the modulus of the vector of the relative sliding velocity of the
teeth working surfaces may be determined by the following equation:
  qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 ð12Þ  ð12Þ
V  ¼ V ¼ ðω1 þ ω2 Þ Ω21 cos 2 β þ f 21 ðλ, Px Þ ð7:49Þ

After transformations we obtain

pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
V ð12Þ ¼ ðω1 þ ω2 Þ f 1 ðλ, Px Þ ctg2 α cos 2 β þ 1 ð7:50Þ

From relations (7.50), it follows that regardless of the type of generating surface,
the vector of the relative sliding velocity lies in the transverse plane of the gear
drives. The relative sliding speed is equal to zero only at the pitch point. With a
variable β, the relative sliding velocity along the gear ring for gears with parallel axes
is a variable.
Figure 7.10 shows the change in the graphs of the relative sliding velocity for the
kinematic shape generation schemes of the 2nd class in the process of interactive
geometry control using the control elements of the shaping system.

Fig. 7.10 Visual analysis of the relative sliding velocity

7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 223

7.7.2 The Total Velocity of Contact Points Movement

in the Direction Perpendicular to the Contact Line

The total velocity of movement of the contact points in the direction perpendicular to
the contact line significantly affects the formation of an oil wedge between the
contacting surfaces. The higher this speed, the better the lubrication conditions for
the interacting surfaces.
ðnÞ
To determine the total velocity V , we first calculate the velocity vector when
the contact point moves along the generating surface (7.11). For this purpose, we
differentiate the expression (7.11) with respect to time t

ðnÞ dλ dμ
V ¼ r λn þ r μn ð7:51Þ
dt dt

We multiply both parts of the expression (7.51) scalarly by the unit vector g
n
perpendicular to the vector V .
n n
As V ⊥q (and also provided that jqj ¼ 1) then V  q ¼ 0 or

 dλ
 dμ
V  q ¼ r λn  q  þ r μn  q 
n
¼ 0: ð7:52Þ
dt dt
dμ
To identify unknowns dλ dt and dt , we add to the Eq. (7.52) the relation obtained by
differentiating the equation of meshing (7.38) with respect to t:

dλ dμ dϕ
F λi þ F μi þ F ϕi ¼ 0: ð7:53Þ
dt dt dt
dμ dϕ
Equations (7.52) and (7.53) contain three unknowns (dλ
dt , dt and dt ), one of which
we will take equal to 1, for instance dt ¼ 1 (1/s). The remaining unknowns are
dϕ

determined by solving the system of Equations (7.52) and (7.53), for example,
according to the Cramer’s rule:
 
 rλ  q r μn  q 
λ  μ
μ  λ

Δ¼ n λ  ¼ rn  q  Fi  rn  q  F i ,
 Fi F μi 
 
 0 r μn  q 
μ  ϕ

Δλ ¼   ¼ rn  q  Fi ,
 F ϕi F μi 
 
 rλ  q 0 

 n
Δμ ¼  λ ϕ 
¼  r λn  q  F ϕi :
 Fi F i

Solving Eqs. (7.52) and (7.53) together, we obtain:

224 B. S. Vorontsov et al.

μ  ϕ
dλ Δλ r  q  Fi
¼ ¼ μ
λ n

dt Δ F i  r n  q  F λi  r μn  q

λ  ϕ ð7:54Þ
dμ Δμ r  q  Fi
¼ ¼  μ
λ n

dt Δ F i  r n  q  F λi  r μn  q

Substituting the obtained expressions (7.54) into (7.51), we obtain the velocity of
the contact point along the generating surface in the coordinate system Sn:

F ϕi 



μ   r λn  r μn  q  r μn  r λn  q
n
V ¼
 ð7:55Þ
F μi  r λn λ
 q  F i  rn  q

Considering that the normal vector is N n ¼ r λn  r μn , and the unit normal vector
en ¼ NN n ,
j nj
!
    N

 N n   ð q  en Þ ¼ N n   q   n  ¼ q  N n ¼ q  r λn  r μn
Nn

μ 

¼ r n  r n  q  r μn  r λn  q
λ

we obtain the dependence:



  
r λn  r μn  q  r μn  r λn  q ¼ N n   ½q  en 

Therefore, we write Eq. (7.45) in the following form:

 
n F ϕi  N n   ½q  en 
V ¼ μ
λ 
 ð7:56Þ
F i  r n  q  F λi  r μn  q

Substituting (7.56) into (7.45), we obtain the velocity of the contact point
movement over the surface of the cut gear in the following form:
 
i F ϕi  N n   ½q  en  ni
Vn ¼ μ

þV : ð7:57Þ
F i  r λn  q  F λi  r μn  q

We direct the vector q along the unit vector of the tangent to the contact lineτ. It
will be equal to [3]
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 225

F μi  r λn  F λi  r μn
q ¼ τ ¼ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

2 : ð7:58Þ
En  ðF μi Þ  2F n  F μi  F λi þ Gn  F λi
2

The partial derivatives of the equation of meshing (7.38) have the form:

F λi ¼ Ω02  cos β  sin α;

F μi ¼  sin β  sin α; ð7:59Þ
F ϕi ¼ Ri sin α,

where Ω02 is derivative of a function Ω2 with respect to λ:


2

f ’2 λ, Py  f ’1 ðλ, Px Þ f ’2 λ, Py  f ”1 ðλ, Px Þ  f 1 ðλ, Px Þ
Ω’2 ¼
’
2 þ
’
2
f 2 λ, Py f 2 λ, Py

 ð7:60Þ
f 002 λ, Py  f 01 ðλ, Px Þ  f 1 ðλ, Px Þ


0
2 þ f 02 λ, Py ¼ 0
f 2 λ, Py

Considering the dependencies (7.13), (7.19), (7.59), (7.60) we transform the

expression (7.58) as follows:

q¼τ



 
sinβ sinα i f 01 ðλ,Px Þþj f 02 λ,Py  cosβk f 02 λ,Py  sinβ
¼ rhffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ffi

0 2

2 i
2
f 1 ðλ,Px Þ þ f 02 λ,Py  sin 2 β sin 2 α0þ Ω02  cos 2 β sin 2 α


Ω02 cosβ sinα j sinβþk cosβ
 rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
h
ffi¼
0
2
0
2 i
0 2
f 1 ðλ,Px Þ þ f 2 λ,Py  sin β sin α0þ Ω2  cos β sin α
2 2 2 2



i sinβ f ’1 ðλ,Px Þþj f ’2 λ,Py  cosβ sinβk f ’2 λ,Py  sin 2 β
¼ rhffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

’ 2

2 i
2
f 1 ðλ,Px Þ þ f ’2 λ,Py  sin 2 βþ Ω’2  cos 2 β

jΩ’2 cosβ sinβkΩ’2 cos 2 β

þ rhffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ¼

’ 2

2 i
2
f 1 ðλ,Px Þ þ f ’2 λ,Py  sin 2 βþ Ω’2  cos 2 β


 

 
i f 01 ðλ,Px Þ sinβþj f 02 λ,Py Ω02 cosβ sinβk f 02 λ,Py  sin 2 βþΩ02 cos 2 β
¼ rhffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2

2 i
2
f 1 ðλ,Px Þ þ f 02 λ,Py  sin 2 βþ Ω02  cos 2 β

ð7:61Þ
226 B. S. Vorontsov et al.

The sought-for velocity of movement of the contact points in the direction

perpendicular to the contact line is defined as the projection of the vector (7.17)
onto the vectorp ¼ τ  en :
 
i F ϕi  N n  ni
uτi ¼ V np ¼ μ
λ 
 þ V  ½τ  en : ð7:62Þ
F i  r n  τ  F λi  r μn  τ

Considering dependencies (7.13), (7.15), (7.16), (7.37), (7.58), (7.61) we trans-

form the expression (7.62) as follows:
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2
0
2ffi
f 1 ðλ, Px Þ þ f 2 λ, Py
uτ1 ¼ rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
h
ffi

0 2 2

2 i
Ω2 cos 2 β þ f 01 ðλ, Px Þ þ f 02 λ, Py  sin 2 β
" #
f 1 ðλ, Px Þ
0
 
 R1 þ 0
 Ω2 cos 2 β þ f 02 λ, Py  sin 2 β ,
f 2 λ, Py
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2

2ffi ð7:63Þ
f 1 ðλ, Px Þ þ f 02 λ, Py
uτ2 ¼ rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
h
ffi

0 2 0
2
0
2 i
Ω2 cos β þ 2 f 1 ðλ, Px Þ þ f 2 λ, Py  sin β 2

" #
f ðλ, Px Þ
0
 
 R2  01
 Ω2 cos 2 β þ f 02 λ, Py  sin 2 β
f 2 λ, Py

To obtain the true values of the velocity, it is necessary to multiply the expression
(7.63) by the angular velocity of the pinion ω1and the gear ω2, respectively.
The total velocity of the contact points movement in the direction perpendicular
to the contact line at ω1 ¼ 1 rad/s
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

’ 2

2ffi
f 1 ðλ, Px Þ þ f ’2 λ, Py
ui ¼ uτ1 þ uτ2 ¼ rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
h
ffi

’ 2 ’
2
’
2 i
Ω2 cos β þ 2 f 1 ðλ, Px Þ þ f 2 λ, Py  sin β 2

" #
f 1 ðλ, Px Þ
0
  1
 2R1 þ 0
 Ω2 cos 2 β þ f 02 λ, Py  sin 2 β  1 
f 2 λ, Py u
ð7:64Þ

Here, u ¼ ωω12 is the gear ratio.

The relation (7.64) is valid for general cylindrical gears with linear contact, when
the contact line in the cutter tool meshing coincides with the contact line of the
working gearing.
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 227

f 1 ðλ, Px Þ  0
 

At 2R1 þ f 02 ðλ, Py Þ
Ω2 cos 2 β þ f 02 λ, Py  sin 2 β  1  1u ¼ 0, the total velocity
of contact points movement uτ ¼ 0. Points of contact for which uτ ¼ 0 should be
excluded from work, because at these points on the surfaces the unfavorable
lubrication conditions are created.

2

2
At f 01 ðλ, Px Þ þ f 02 λ, Py ¼ 0, the modulus of the normal vector to the
generating surface vanishes, which indicates the presence of singular points on the
surface.

7.7.3 Specific Sliding Coefficients

It would be wrong to estimate wear only by the relative sliding speed of the working
surfaces. For a more objective assessment of the tooth wear, the specific sliding
coefficients are used. The specific sliding coefficients for the pinion and the gear are
determined respectively by the formulas [3]:
h i2 h i
12 12 2
V V
η1 ¼ 1 12
; η2 ¼ 2 12
, ð7:65Þ
V nV V nV
1 2
where V n, V n are velocities of the contact points movement on the cut surfaces in the
direction of the relative speed. These velocities can be determined from the
Eq. (7.57) by substituting the vector q by the unit vector k of the applicate axis,
12
which is perpendicular to the vector of the relative velocity V n .
Considering the expressions (7.13), (7.15), (7.17), (7.59), we obtain:
 

i i  Ω1  cos β þ f 1 ðλ, Px Þ  Ri f 02 λ, Py ni
Vn 
¼ 0
  þV ð7:66Þ
Ω2 cos 2 β þ f 02 λ, Py  sin 2 β  f 1 ðλ, Px Þ

Substituting the values (7.40), (7.47), and (7.66) into expression (7.65), we
determine the specific sliding coefficients:

 uþ1
ηi ¼ u
ð7:67Þ
Ri f 02 ðλ, Pу Þ
f 1 ðλ, Px Þð
1
Ω02 cos 2 βþ f 02 ðλ, Pу Þ sin βÞ
2

From the ratio (7.67), it follows that the specific sliding coefficients depend on the
geometrical dimensions of the gearing, the gear ratio, the teeth curve of the gener-
ating surface and the initial contour.
At the pitch point where f1(λ, Pх) ¼ 0, the specific sliding coefficients are
equal to
zero. They are also equal to zero in the case when Ω02  cos 2 β þ f 02 λ, Py 
228 B. S. Vorontsov et al.

ð12Þ
sin 2 β ¼ 0. In this case, the vector of the relative velocity V coincides with the
direction of the contact line. In this case, the speed of movement of the contact points
in the direction of the relative speed vector is equal to infinity.
When the following condition is met


Ri f 02 λ, Py


 1¼0
f 1 ðλ, Px Þ  Ω02 cos 2 β þ f 02 λ, Py  sin 2 β

singular points appear on the surface of the teeth being cut. At these points, the
specific sliding coefficients are equal to infinity. These points on the surfaces of the
pinion and the gear teeth must be excluded from work.

7.7.4 The Angle Between the Relative Velocity

and the Direction of the Contact Line

The value of the angle between the relative sliding speed of the teeth working
surfaces and the direction of the contact line, as well as the total velocity, has a
significant effect on the formation of an oil wedge between the contacting surfaces.
The closer this angle to the right angle, the better the lubrication conditions for the
contacting surfaces.
The tangent of an angle can be determined by the formula [3]:
 
 12 
τ  V 
tgν ¼ 12
, ð7:68Þ
τV

or, considering (7.13), (7.47), (7.58), (7.59) after transformations we will have:
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2

2ffi
f 1 ðλ, Px Þ þ f 02 λ, Py
tgν ¼
sin β  cos β


Ω02  cos 2 β þ f 02 λ, Py  sin 2 β


0 2

2 ð7:69Þ
f 02 λ, Py  Ω2 0  f 1 ðλ, Px Þ þ f 02 λ, Py

From the relation (7.69), it follows that the angle between the velocity of the
relative movement of the teeth surfaces and the direction of the contact line ν is equal
to 90 :
For β ¼ 0, i.e., in the sections of the gear ring, where the helix angle of the
generating surface is equal to zero
For β ¼ π/2, which is unrealistic for cylindrical gearing
When the following equality is satisfied:
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 229


0 2

2
f 02 λ, Py  Ω02  f 1 ðλ, Px Þ þ f 02 λ, Py ¼0


0 2
When equality Ω02  cos 2 β þ f 02 λ, Py  sin 2 β ¼ 0 or f 1 ðλ, Px Þ þ

0
2
f 2 λ, Py ¼ 0 is satisfied, angle ν ¼ 0, which is unfavorable for the formation
of an oil wedge.

7.7.5 The Reduced Curvature of the Teeth Surfaces

in the Direction Perpendicular to the Contact Line

The reduced curvature is one of the main performance indicators affecting the
contact strength of the tooth surfaces. The smaller the relative curvature, the larger
the contact area of the teeth surfaces, and, consequently, the less the contact
destruction of the teeth. The largest reduced curvature of the contacting surfaces of
teeth is in the section perpendicular to the contact line; therefore, the contact strength
of the gear teeth is assessed by its value.
The reduced normal curvature is equal to [3]:

χ r ¼ χ ð1Þ  χ ð2Þ , ð7:70Þ

where χ (1), χ (2)are the normal curvatures of teeth surfaces of the pinion and the gear,
respectively, in the common normal section. They can be expressed in terms of the
curvature of the generating surface [3]:

χ ðiÞ ¼ χ ðnÞ  χ ðriÞ ð7:71Þ

Here, χ (n)is the curvature of the generating surface in the common normal section
and χ ðriÞ is the reduced curvature of the generating surface and the surface of the cut
gear in the same section.
Then (7.70) can be transformed as follows [3]:

χ r ¼ χ ðr 1Þ þ χ ðr 2Þ ð7:72Þ

The reduced curvature of the generating surface and the surface of the cut gear in
the direction perpendicular to the line of contact according to [3] are determined by
the ratio

2
En ðF μi Þ  2F n F λi F μi þ Gn F λi
2
χ ðr iÞ ¼ , ð7:73Þ
Δi

where
230 B. S. Vorontsov et al.

 
E rn λ 
ðniÞ
 n En V 
 
 ðniÞ 
Δi ¼  F n Gn V rn μ  ð7:74Þ
 
 
 Fλ F μi F ϕ 
i i

or considering (7.13), (7.19), (7.40), (7.59), we obtain:

 2
 qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi

0 2

2ffi
Δi ¼ r 0n   f 02 λ, Py  f 1 ðλ, Px Þ þ f 02 λ, Py 
" #
f 1 ðλ, Px Þ
0
  ð7:75Þ
 Ri  0
 f 2 λ, Py  sin 2 β þ Ω02  cos 2 β
f 2 λ, Py

The reduced curvature χ r after transformations:


f 02 λ, Py
χ ir ¼ h


2 i32
ð f 1 0 ðλ, Px ÞÞ þ f 02 λ, Py
2

h
2

2
2 i
f 01 ðλ, Px Þ þ f 02 λ, Py  sin 2 β þ Ω02  cos 2 β
  ð7:76Þ


 
Ri  ff0 1 ðλ,λ, PPx Þ f 02 λ, Py  sin 2 β þ Ω02  cos 2 β
2ð yÞ

Substituting (7.76) in (7.72), we obtain the sought-for the reduced normal

curvature of the contacting surfaces of the teeth in the direction perpendicular to
the contact line:


ðR1 þ R2 Þ  f ’2 λ, Py
χr ¼ h

’ 2

2 i32
f 1 ðλ, Px Þ þ f ’2 λ, Py
1
" #


f 1 ðλ, Px Þ ’ ’

 
R1 þ ’
 Ω2 cos β þ f 2 λ, Py  sin β
2 2
ð7:77Þ
f 2 λ, Py
h

2

2 i
Ω02 cos 2 β þ f ’1 ðλ, Px Þ þ f ’2 λ, Py
2
 sin 2 β
 " #
f 1 ðλ, Px Þ
0 ’

 2 
R2 
 Ω2  cos β þ f 2 λ, Py sin β
2
f 2 λ, Py

Figure 7.11 shows the graphs obtained for a comparative visual analysis of the
reduced curvature of the teeth surfaces in the direction perpendicular to the contact
line in the process of interactive geometry control using the control elements of the
shaping system.
7 Interactive Control of the Teeth Gear Shaping in the Cutting Tools Design 231

Fig. 7.11 Analysis of the reduced curvature of the teeth surfaces in the direction perpendicular to
the contact line

7.8 Conclusion

The use of common unified parameters will allow integrating the shape generation
system, which includes a preliminary assessment of the geometry and kinematics of
the process, into automated design, production, analysis, and control systems.
Methodologies, algorithms, and software for interactive control of surface shape
generation, unification of control parameters, determination of contact points, opti-
mized synthesis of complex surfaces, based on the mathematical models obtained in
the work, allow the development of computer-integrated systems for shaping com-
plex surfaces with computer-aided design and interactive control.

References

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