machines
Article
The Profiling of Hob Mill Used for Generating a Cycloidal
Reducer’s Disk
Georgiana-Alexandra Moros, anu 1,2 , Virgil Gabriel Teodor 1,3, *
Citation: Moros, anu, G.-A.; Teodor,
V.G.; Baroiu, N. The Profiling of Hob
Mill Used for Generating a Cycloidal
Reducer’s Disk. Machines 2023, 11,
518. https://doi.org/10.3390/
machines11050518
Academic Editor: Gianni
Campatelli
Received: 5 April 2023
Revised: 22 April 2023
Accepted: 26 April 2023
Published: 1 May 2023
Copyright: © 2023 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Machines 2023, 11, 518. https://doi.org/10.3390/machines11050518
and Nicus, or Baroiu 1,3
1 Research Center in Manufacturing Engineering Technology (ITCM), “Dunarea de Jos” University of Galati,
800201 Galati, Romania; alexandra.costin@ugal.ro (G.-A.M.); nicusor.baroiu@ugal.ro (N.B.)
2 Department of Thermal Systems and Automotive Engineering, “Dunarea de Jos” University of Galati,
800201 Galati, Romania
3 Department of Manufacturing Engineering, “Dunarea de Jos” University of Galati, 800201 Galati, Romania
* Correspondence: virgil.teodor@ugal.ro; Tel.: +40-0336-130-208
Abstract: This paper presents the profiling of the hob mill designed to generate the active surface of
the cam of a cycloidal reducer. The algorithm allows determining the active surface of the generating
rack gear, which is reciprocally enveloping with the active surface of the cycloidal disk. The novelty
of the algorithm, based on the determination of the intermediate surface, consists in the fact that an
innovative method of determining this surface is used, called the “virtual pole” method. The method
allows determining the enwrapping curve of an ordered curl of surfaces, generated in the rolling
movement of two conjugated centrodes. Using the “virtual pole” method, the calculation time for
tool profiling is significantly reduced and the disadvantage of the resulting error, small enough to be
neglected from a technical point of view, is fully compensated by this reduction in calculation time.
Keywords: virtual pole method; cycloidal reducer; gearing pole; intermediate surface
1. Introduction
Cycloidal reducers ensure very high reduction ratios, in some cases exceeding values
of 200:1. Among their advantages are the lack of gaps between the active elements, the
fact that between these elements there is rolling and not sliding friction, high resistance
to shocks and silent operation. All of these advantages have made them used in the
automotive industry, in machine tools, robotics etc. [1–4].
One of the main parts of this type of reducer is the cycloidal disk, which has lobes that
are in contact with the cylindrical surfaces of some bolts [5].
The cycloidal disk has radial symmetry, its shape recommending it for machining with
tools that generate by enwrapping, for example hob mills [6,7].
This type of tool has the advantage of high productivity, as well as an increased
processing precision, due to the fact that the profile errors of the tool are transposed much
less on the profile of the generated part.
K.S. Lin et al. [8] approached kinematic errors and tolerance for cycloidal gear reducers.
Geometry, accuracy and manufacturing parameters were studied using the gearing theory.
The distribution of kinematic errors of cycloidal reducers was investigated using the
Monte Carlo method. Based on the equation of the tooth surface of the cycloidal gear, G.
Liu et al. [9] performed a simulation of cycloidal tooth profiles using MATLAB software to
establish the precision and accuracy of cycloidal gear transmission.
Modifications regarding the active form of the cycloidal disk, as well as studies related
to kinematic errors, efficiency of reducers and gear damage were also made by other
authors, such as I. Komorska [10], R. Król [11], H. Tariq [12] and K. Olejarczyk [13].
https://www.mdpi.com/journal/machines
Machines 2023, 11, 518 2 of 21

Other authors have studied the technology of generating helical surfaces end mill
tools, P. Borla [14], or with side mill tools, L. Zhou [15].
Last but not least, a number of authors, among them, T.S. Lai [16], Y. Peng et al. [17]
and C. Liu et al. [18], focused on the calculation of the geometry of the active elements of
this type of reducers.
There are three ways of obtaining machined surfaces frequently used in the technique.
These surfaces can be obtained as trajectories of a point, as envelopes of successive positions
of a body, or finally as envelopes of successive positions of a curve.
The first of the cases can be exemplified by turning, the second by milling, with
front cylindrical tools or disk cutters, and the last case, by generation with rack-type tools,
gear- shaped cutters or hob mills.
The generation of surfaces by milling is characterized by high productivity and by
the fact that surfaces of a complicated shape can be obtained. The disadvantage of this
processing method is that the precision and quality of the obtained surfaces depends, to a
great extent, on the machine tool used and very expensive machine tools are needed for
mass production.
Generation by enwrapping is characterized by high productivity and surface precision,
comparable to those obtained by the previously presented method.
Another feature of this method is that the generated surface profile is obtained by
a large number of cuts, which makes the shape errors of the cutting edge have a lower
influence on the accuracy compared to the other generation modes.
Last but not least, used machine tools are much cheaper compared to the CNC ma-
chines required for milling operations.
However, enwrapping generation requires determination of the cutting tool profile,
which profile will be a reciprocally enveloping curve with the generated profile of the part.
This profiling step can be very laborious and is prone to introducing errors into the tool
design process.
In order to improve tool profiling methods, alternatives to classical analytical methods
have been developed.
These alternatives allow either a calculation that is easier to perform, but applicable
only to a limited range of profiles, or a calculation with more general applicability but with
a higher degree of approximation. In this paper, the advantages of the two alternatives
are combined, an algorithm for the generation of surfaces known in analytical form being
imagined and presented. The algorithm implies the determination of the active surface
of the generating rack gear, which is reciprocally enwrapping to the active surface of the
cycloidal disk [19–24].
The novelty of the algorithm, based on the determination of the intermediate surface,
consists in the fact that it uses an innovative method for determining this surface, called
the “virtual pole method” [25,26].
The “virtual pole” method is based on the Willis theorem and starts from the premise
that: “a normal to the profile to be generated, taken through any point of it, will intersect
the centrode associated with this profile” [25–28].
The method allows determining the enwrapping curve of an ordered curl of surfaces,
generated in the rolling movement of two conjugated centrodes.
Figure 1 shows the reference systems used: xy represents the fixed reference system,
having the origin at point O; XY—mobile reference system, joined with the part; ξη—mobile
reference system, joined with the tool, with the origin at point O1 , as well as the centrodes
C1 , associated with the part and C2 , associated with the tool.
Machines 2023,
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Figure1.1.The
Figure Theprinciple
principle of the
of the “virtual
“virtual pole”
pole” method.
method.

The
Theinitial
initialpositions
positions of the mobile
of the systems
mobile associated
systems with the
associated part
with theand theand
part tool the
weretool were
denoted by XY and ξη and by X0 Y0 and ξ 0 η 0 , the positions of the same systems after they
denoted by XY and ξη and by X′Y′ and ξ′η′, the positions of the same systems after they
were moved, so that the “virtual pole” Pv occupies the position of the gearing pole, P.
wereThemoved, so that the “virtual pole” Pv occupies the position of the gearing pole, P.
position represented by a continuous line for Σ profile corresponds to the initial
Thewhile
moment, position represented
the position by a continuous
represented linecorresponds
by a dashed line for Σ profiletocorresponds
the moment whento the initia
moment, while the position represented
the “virtual pole” overlaps the gearing pole. by a dashed line corresponds to the momen
when Thetheabsolute
“virtual pole” overlaps
movements the the
by which gearing pole.
mobile reference systems move are: I repre-
sents The absolutemovement
the rotational movements by XY
of the which thearound
system mobilepoint
reference
O and systems move are: I repre
II—the translational
movement of the system along the axis.
sents the rotational movement of the XY system around point O and II—the translationa
ξη η
→
movement of the ξηpoint
The intersection system along
between N Σthe η axis.taken to the profile to be generated Σ, and
normal,

the centrode associated with
The intersection point thebetween
part is theN“virtual
Σ normal, Pv . Subsequently,
pole”,taken to the profile by to
applying to
be generated Σ
the part the absolute movement that it performs during processing,
and the centrode associated with the part is the “virtual pole”, Pv. Subsequently, by ap the “virtual pole” is
brought
plying to to the
the gearing
part thepole, P.
point movement
absolute that it performs during processing, the “virtua
In this position, the current point MC , through which the normal to the profile was
pole” is brought to the gearing pole, point P.
taken, is in contact with a point from the tool profile, point MT .
Inaddition,
In this position, the current
the tangency point Mthe
point between C, through which the normal to the profile was
tool profile S and the part profile Σ, the
taken,Mis
point C ≡in
M contact
T , is, at with
this a point
moment, from
on the the
contact tool profile,
curve CC. point MT.
In addition, the tangency point between
Once the intermediate surface of the generating rack gear the tool profile S and the
is known, part profile
its envelope is Σ, the
point MC≡M
determined T, is,
with a at this moment,
cylindrical on thepitch
and constant contact curve
helical CC. representing the primary
surface,
peripheral
Oncesurface of the worm surface
the intermediate tool. of the generating rack gear is known, its envelope is
This paper
determined with hasaacylindrical
structure that andconsists
constant of six main
pitch sections.
helical surface, representing the primary
This section, Introduction,
peripheral surface of the worm tool. presents the state of art of the analyzed problem.
In Section 2, Methodology for profiling the hob mill, the methodology used to develop
This paper has a structure that consists of six main sections.
the proposed algorithm for profiling the hob mill is presented, by using the intermediate
This section, Introduction, presents the state of art of the analyzed problem.
surface method and the virtual pole method.
In Section
Section 3, Hob Two,mill Methodology
for processing the fordisk profiling the hob
of a cycloidal mill, develops
reducer, the methodology
the mathe- used to
develop the proposed algorithm for profiling the hob mill
matical equations used to apply the algorithm in the case of the study of the enwrapping is presented, by using the inter
mediateasurface
between methodand
helical surface and the virtual
a surface withpole radialmethod.
symmetry. The stages of determining
the equations
Section of the theoretical
Three, Hob mill cycloidal profile, establishing
for processing the disk of thea position
cycloidalof the virtual develops
reducer, pole, the
finding the enwrapping condition, identifying the intermediate
mathematical equations used to apply the algorithm in the case of the study of the en surface and the primary
peripheral
wrappingsurfacebetween of the hob millsurface
a helical tool areand presented.
a surface with radial symmetry. The stages o
In Section 4, Numerical application for profiling the hob mill for processing the disk
determining the equations of the theoretical cycloidal profile, establishing the position o
of a cycloidal reducer, an example of a practical application of the proposed algorithm is
the virtual pole, finding the enwrapping condition, identifying the intermediate surface
presented. In the last column of ” the table were we present the coordinates of the points
and the primary
belonging peripheral
to the profile surface ofand
to be generated theto hobthemill toolofare
profile thepresented.
generating tool, in this
In the
section, Section
valueFour, of theNumerical
equation ofapplication
the winding forcondition
profilingis the hob
given formill
the for processing the
numerical
disk of performed
solution a cycloidalwith reducer,
the helpanofexample
the Octaveofprogram.
a practical application of the proposed algo
rithm is presented. In the last column of ” the table were we present the coordinates of the
points belonging to the profile to be generated and to the profile of the generating tool
in this section, the value of the equation of the winding condition is given for the numer
ical solution performed with the help of the Octave program.
Machines 2023, 11, 518 4 of 21

Since theoretically the value of the equation is zero, we can consider that the non-zero
values represent errors in the identification of points on the intermediate surface. Consider-
ing the very low values obtained, we can state that the errors are negligible.
In Section 5, an analysis and interpretation of the obtained results is made.
Section 6 is reserved for the presentation of established conclusions.

2. Methodology for Profiling the Hob Mill

The implementation of the proposed algorithm involves going through some prede-
fined calculation stages.
First, the analytical equations of the profile to be generated are established, equations
dependent on the parameter u.
Afterwards, the profile of the generating rack of this profile is determined. To achieve
this stage, the equations of the virtual pole coordinates are determined based on the
analytical equations of the previously determined profile.
Since the position of the virtual pole depends on the considered point on the profile to
be generated and on the relative movement between the blank and the tool, its equations
will depend on two independent parameters. One of them is the parameter u, which
sets the position of the current point on the profile to be generated, and the other is the
parameter ϕ, which sets the relative position between the tool and the workpiece.
Once the position equations of the virtual pole are determined, the enwrapping condi-
tion can be determined, which is actually a link between the two independent parameters,
a link that only appears when the current point on the profile comes into contact with the
cutting tool edge.
Thus, is determined the profile of the tool which will generate the desired profile of
the piece. Due to the existence of the enwrapping condition, this profile again depends on
a single parameter, respectively u.
The profile thus obtained will represent the generating curve of the intermediate
surface, respectively the primary peripheral surface of the rack tool.
The analytical solution of the winding condition may be impossible to find, if it
represents a transcendental equation, and therefore, in the paper, a method of numerical
solution of this condition is proposed.
The proposed solution involves the use of the “fzero” function provided by the
Octave program.
This command allows finding the value of the variable for which a given objective
function has a value close to zero. Basically, the command performs an iterative calculation
of the values of the objective function, between two given values of the variable and returns
both the value of the variable and the value of the function corresponding to this variable.
The continuation of the algorithm involves the determination of the characteristic
curve on the intermediate surface. As is known, according to the Nikolaev theorem, “the
characteristic curve of a cylindrical surface, reciprocally enwrapping with a cylindrical
helical surface of constant pitch, is the geometric locus of the points where the normal to
the cylindrical surface intersects the axis of the helical surface” [25,29].
The analytical solution of the characteristic curve equations is much more complicated,
often requiring a numerical solution.
According to the proposed algorithm, the intermediate surface is approximated by a
cloud of points whose coordinates are known in discrete form.
According to the Nikolaev theorem, among the points belonging to this cloud, will
also belong to the characteristic curve, only those points where the normal to the surface
intersects the axis of the tool.
The identification of these points is done by fixing two of the coordinates of the points
and solving the enwrapping condition for the third coordinate.
After finding the characteristic curve, a helical motion is given on it, generating the
primary peripheral surface of the hob mill tool.
Machines2023,
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The axial section

The section of
ofthe
thetool
toolisisdetermined
determined byby
intersecting thethe
intersecting primary peripheral
primary sur-
peripheral
face with
surface an an
with axial plane.
axial plane.
Inthe
In thefollowing,
following,these
thesestages
stagesarearedetailed
detailedfrom
fromaamathematical
mathematicalpoint
pointof
ofview.
view.

3.
3. Hob
Hob Mill
Mill for
for Processing
Processingthe
theDisk
Diskof
ofaaCycloidal
CycloidalReducer
Reducer
Figure
Figure 2 shows the generation with the rack geartool,
2 shows the generation with the rack gear tool,the
thereference
referencesystems,
systems,as
aswell
well
as
asthe
theconjugated
conjugatedaxodes.
axodes.

Figure2.2. Generating
Figure Generatingwith
withrack
racktool.
tool. Reference
Referencesystems
systemsand
andconjugated
conjugatedaxode.
axode.

The
The following
following are defined: A
are defined: A11—axode
—axode of of the part; A
the part; A22—axode
—axode of of the
the rack
rack gear
gear tool;
tool;
xyz—the
xyz—thefixed
fixedreference
referencesystem,
system,having
having z axis
thethe superimposed
z axis superimposed on on
thethe
axisaxis of A
of the 1 axode;
the A1 ax-
XYZ—the
ode; XYZ—themobilemobile
reference system,system,
reference joined with
joined thewith
part,the Z axis
thepart, thebeing superimposed
Z axis being superim- on
the z axis of the fixed system; ξηζ mobile reference system, joined with
posed on the z axis of the fixed system; ξηζ mobile reference system, joined with the tool. the tool. The A 2
axode belongs to the plane determined by the η and
The A2 axode belongs to the plane determined by the η and ζ axes.ζ axes.
The
The observation
observation is made that
is made that the
the projection
projectionin inthe
theXY XYplane theAA
planeofofthe 1 axode
1 axode is is
thethe
C1
Ccentrode,
1 centrode, a circle of radius R
a circle of radius Rrp, and , and the projection in the ξη plane
rp the projection in the ξη plane of the A2 axode of the A axode
2 deter-
determines
mines the Cthe C2 centrode,
2 centrode, whichwhich is a line.
is a line.
The
The kinematics of the rolling process of
kinematics of the rolling process of the
the two
two axodes
axodes respects
respects the
the rolling
rolling condition:
condition:
δ =δ R
=rpR· ϕ,⋅ϕ, (1)
rp (1)
where Rrp represents the rolling radius of the blank and ϕ the rotation angle of the reference
where Rrp represents the rolling radius of the blank and φ the rotation angle of the refer-
system associated with the profile to be generated.
ence system associated with the profile to be generated.
The absolute movements that occur during rolling are:
The absolute movements that occur during rolling are:
-- the
the rotation
rotationof theCC1 1centrode
ofthe aroundz zaxis,
centrodearound axis,rotation having
rotation thethe
having angular parameter
angular parameterϕ:
φ:
x = ω3T ( ϕ)· X, (2)
where ω3T is the rotation matrix.
x = ω T
3
ϕ ⋅( )
X, (2)

- the translation
T of the C2 centrode in a parallel direction to the y axis:
where ω3 is the rotation matrix.
- the translation of the C2 centrode in a parallel R
direction to the y axis:
 
rp
x = ξ + A, A = , (3)
δ
where A represents the translation matrix and δ—the translation of the reference system,
joined with the rack gear tool.
  Rrp 
x = ξ + A, A = 
 δ 
, (3
 
where A represents the translation matrix and δ—the translation of the reference system
Machines 2023, 11, 518 joined with the rack gear tool. 6 of 21

3.1. Equations of the Theoretical Cycloidal Profile

The cycloidal
3.1. Equations profile is
of the Theoretical described
Cycloidal by a point M, joined with a circle of radius r (rou
Profile
letteThe
radius), which
cycloidal rolls
profile outside the
is described by abase,
point with a circle
M, joined withofa circle
radius of R (baser (roulette
radius radius), Figure
[21]. which rolls outside the base, with a circle of radius R (base radius), Figure 3 [21].
radius),

Figure3.3.Generating
Figure Generating with
with rack
rack tool.
tool. Reference
Reference systems,
systems, conjugated
conjugated axodes
axodes and cycloidal
and cycloidal profile profile
(withpurple
(with purple line).
line).

Four
Fourreference systems
reference will will
systems be used to identify
be used the cycloidal
to identify profile: profile:
the cycloidal
-- XX0Y0Y 0Z
0Z0 0isisthe
the reference
reference systemsystem in which
in which the coordinates
the coordinates of Mare
of M point point are defined;
defined; the th
roulette
roulette is is
defined in this
defined reference
in this system;
reference system;
-- XX1Y1Y1Z
1Z1 —the reference system with the same origin as the X0 Y0X
1—the reference system with the same origin as the
Z00Ysystem, which
0Z0 system, which ro
rotates around the Z0 axis with the angular parameter u (variable parameter which
tates around the Z0 axis with the angular parameter u (variable parameter which de
describes the profile of the part); in this way, the M point describes a circle of radius a
scribes the profile of the part); in this way, the M point describes a circle of radius
(the distance between the generating point of the cycloidal profile and the center of
(the distance between the generating point of the cycloidal profile and the center o
the roulette);
- Xthe roulette);
2 Y2 Z2 —mobile reference system having the axes X2 ||X1 ; Y2 ||Y1 ; Z2 ||Z1 and the
- origin2Z
X 2Y O2—mobile
offset from reference
the O1 withsystem
the valuehaving
(R + r);the axes X2||X1; Y2||Y1; Z2||Z1 and th
- origin O mobile
XYZ—the offset from the O
reference 1 with joined
system, the value
with(R the+ profile
r); to be generated Σ; the Z
- axis coincides with the Z axis and the X Y
XYZ—the mobile reference system, joined with the profile
2 2 2 Z 2 system rotates towards
to be to the XYZ Σ; the
generated
system, around the
axis coincides with the Z ≡ Z axis, with the angle v (the rotation
2 Z2 axis and the X2Y2Z2 system rotates towardsparameter of the X2to
Y2 the XY
reference system).
system, around the Z≡Z2 axis, with the angle v (the rotation parameter of the X2Y
Inreference
Figure 3, the position indicated by the continuous line for the roulette corresponds
system).
to the initial moment, while the position indicated by the dashed line corresponds to a
Inwith
rotation Figure 3, theof
an angle position indicated
v 6= 0. The by the continuous
same observation applies toline
the for
axesthe roulette
of the correspond
reference
to the the
system, initial
axesmoment,
being the while
notation the
forposition indicated
the new axes byXthe
position dashed line corresponds to
0 Y0 Z0 .
rotation with anprofile
The cycloidal angleisof v ≠ 0.curve,
a plane The same observation
therefore, generatingapplies to the
this profile andaxes of the referenc
determining
system,
the profilethe axes
of the being
rack gearthe notation
tool, which generates the Σ
for the new axes position
T profile, X0Y
can be 0Z0.
treated as a plane
enwrapping problem profile
The cycloidal and canisbea studied XY plane. generating this profile and determin
in the therefore,
plane curve,
Point M has the following coordinates:
ing the profile of the rack gear tool, which generates the ΣT profile, can be treated as
plane enwrapping problem and can beXstudied in the XY plane.
0 = a;
M:
Point M has the following coordinates: (4)
Y0 = 0.

In the relative movement of system X0 Y0 to system X1 Y1 ,

X1 = ω3T (u)· X0 , (5)

Machines 2023, 11, 518 7 of 21

which, developed, can be written:

      
X1 cos u − sin u a a· cos u
= · = , (6)
Y1 sin u cos u 0 a· sin u

the M point describes the circle of equations:

X1 (u) = a· cos u;
MX1 Y1 : (7)
Y1 (u) = a· sin u.

The coordinate transformation between the reference systems X2 Y2 and X1 Y1 is:

 
R+r
X2 = X1 + A; A = (8)
0

or, developed:        
X2 X1 R+r R + r + a· cos u
= + = . (9)
Y2 Y1 0 a· sin u
Therefore, in the X2 Y2 system, the trajectory of point M will be a plane curve:

X2 (u) = R + r + a· cos u;
MX2 Y2 : (10)
Y2 (u) = a· sin u.

The movement of the X2 Y2 system with towards to the XY system is given by the
equation:
X = ω3T (v)· X2 , (11)
which can be developed by the form:
      
X cos v − sin v R + r + a· cos u ( R + r )· cos v + a· cos(u + v)
= · = . (12)
Y sin v cos v a· sin u ( R + r )· sin v + a· sin(u + v)

The transmission ratio is defined as i = Rr and, taking into account the rolling condition
of the roulette with towards to the base, it results:
r
r ·u = R·v ⇒ v = ·u = i ·u, (13)
R
from Equation (12), the cycloidal profile equations are obtained:

X (u) = a· cos(1 + i )·u + ( R + r )· cos(i ·u);

ΣT : (14)
Y (u) = a· sin(1 + i )·u + ( R + r )· sin(i ·u).

Note: For the cycloidal profile to be a closed curve, the condition R/r = n must be
respected, i = n, n being an integer number.

3.2. Determining the Position of the ”Virtual Pole”

The direction of the normal to the ΣT profile is given by the equation:
→ . → . →
N Pv = Y u · i − X u · j . (15)
. .
In Equation (15) X u and Y u represents the partial derivatives of the equations X(u)
and Y(u) (Equation (14)) in relation to the u variable:
.
X u = − a·(1 + i )· sin(1 + i )·u − ( R + r )·i · sin(i ·u);
. (16)
Y u = a·(1 + i )· cos(1 + i )·u + ( R + r )·i · cos(i ·u).
 In Equation (15)

X and

Y represents the partial derivatives of the equations X(u)
u u
and Y(u) (Equation (14)) in relation to the u variable:
 = −a ⋅ ( 1 + i ) ⋅ sin ( 1 + i ) ⋅ u − ( R + r ) ⋅ i ⋅ sin ( i ⋅ u) ;
Xu
Machines 2023, 11, 518 8 (16)
of 21
 = a ⋅ ( 1 + i ) ⋅ cos ( 1 + i ) ⋅ u + ( R + r ) ⋅ i ⋅ cos ( i ⋅ u) .
Yu

The normal to the ΣT profile intersects the C1 circle, of Rrp radius, at the distance λ
fromThe normal point
the current ΣTofprofile
to theM, intersects
coordinates the
X(u), C1 circle,
Y(u), Rrp radius, at the distance λ
Figureof4 [22].
from the current point M, of coordinates X(u), Y(u), Figure 4 [22].

Figure 4. Determining the position of the “virtual pole”.

Therefore, the N P vector, the normal vector, with the origin at the current point on
→
v
the ΣTherefore, the N P vector, the normal vector, with the origin at the current point on
T profile and with vthe top in the “virtual pole” (belonging to the circle of radius Rrp ),
the
has Σ T profile
the and with the top in the “virtual pole” (belonging to the circle of radius Rrp),
equation:
has the equation:
→ →
N PvN= [=a·( · · · i +
 a ⋅ ( 1 + i ) ⋅ cos ( 1 + i ) ⋅ u + ( R + r ) ⋅ i ⋅ cos ( i ⋅ u→)  ⋅ λ ⋅ i +
 1 + i )· cos ( 1 + i )· u + ( R + r )· i cos ( i u )]·
 λ
Pv (17)
+[ a+·(1a + · · · . (17)
 ⋅ ( 1 + i ) ⋅ sin ( 1 + i ) ⋅ u + ( R + r ) ⋅ i ⋅ sin ( i ⋅ u )  ⋅ λ ⋅ j .
i )· sin ( 1 + i )· u + ( R + r )· i sin ( i u )]· λ j

At the
At the same
same time,
time, the
the position
position vector
vector of
of the
the current point M
current point M is:
is:
 →  → →
→
r =r X=(X u)· ( ui) ⋅+i +YY(u()·u )j⋅ j== [aa· ⋅cos
cos((11+ ) ⋅ uu +
+ ii )· + ((RR++r )r⋅)·
cos ( i(⋅iu·u))]·⋅ i i++
cos
→  (18)
+(i1)·+ui +
 a (⋅ 1sin
+[ a·+sin ) ⋅ u( R+ (+R r+)·r sin
) ⋅ sin
(i ·(ui)]·
⋅ u )j.⋅ j .
→

Thus, the
the position
position vector
vector of the PPvvpoint
of the pointisisobtained
obtainedby
bysumming
summingthe vectorsN
thevectors NPPvv
→
and rr :
→ → →
r Pv = N Pv + r = {[ a·(1 + i )· cos(1 + i )·u + ( R + r )·i · cos(i ·u)]·λ +
→
+ [ a· cos(1 + i )·u + ( R + r )· cos(i ·u)]}· i + (19)
+{[ a·(1 + i )· sin(1 + i )·u + ( R + r )·i · sin(i ·u)]·λ+
→
+ [ a· sin(1 + i )·u + ( R + r )· sin(i ·u)]}· j .
→
In principle, the r Pv vector can be written as follows:

→ → →
r Pv = XPv · i + YPv · j . (20)

Taking into account the fact that the point Pv also belongs to the circle of radius Rrp ,
with the equations:
X = Rrp · cos ϕ;
C1 : (21)
Y = Rrp · sin ϕ,
Machines 2023, 11, 518 9 of 21

the coordinates of the “virtual pole” point can be obtained from the Equations (19) and (21),
in the form:

[ a·(1 + i )· cos(1 + i )·u + ( R + r )·i · cos(i ·u)]·λ+

+[ a· cos(1 + i )·u + ( R + r )· cos(i ·u)] = Rrp · cos ϕ;
Pv : (22)
[ a·(1 + i )· sin(1 + i )·u + ( R + r )·i · sin(i ·u)]·λ+
+[ a· sin(1 + i )·u + ( R + r )· sin(i ·u)] = Rrp · sin ϕ.

3.3. Determination of the Enwrapping Condition

The enwrapping condition must be determined as a relation between the independent
parameters u and ϕ, so that the profile of the generating rack gear is the enveloping curve
for the family of curves obtained during the relative movement of the XY system towards
to the ξη system.
If the parameter λ is removed from the system of Equation (22),

Rrp · cos ϕ− a· cos(1+i )·u−( R+r )· cos(i ·u)

λ= a·(1+i )· cos(1+i )·u+( R+r )·i · cos(i ·u)
=
Rrp · sin ϕ− a· sin(1+i )·u−( R+r )· sin(i ·u) (23)
= a·(1+i )· sin(1+i )·u+( R+r )·i · sin(i ·u)
,

the specific form of the enwrapping condition is obtained:

Rrp · a·(1 + i )· sin[(1 + i )·u − ϕ] + Rrp ·( R + r )·i ·

(24)
· sin(i ·u − ϕ) − ( R + r )· a· sin u = 0.

Basically, the equation (24) represents a dependency of type:

ϕ = ϕ ( u ). (25)

3.4. Determination of the Intermediate Surface

Machines 2023, 11, x FOR PEER REVIEW It should be taken into account that the active profile of the disk from the cycloidal
10 of 23

reducer is an equidistant curve to the theoretical cycloid given by Equation (14) [26,27].
The distance at which the real profile is compared to the theoretical profile is equal to
The distance at which the real profile is compared to the theoretical profile is equal
the radius of the bolts, rb , which
to the radius of the bolts, rb, which
materializes the inner gearing surface.
materializes the inner gearing surface.
Figure 5 shows the theoretical cycloidalcycloidal
Figure 5 shows the theoretical profile andprofile
the real and the real profile.
profile.

Figure 5. The theoretical cycloidal profile and the real profile.

Figure 5. The theoretical cycloidal profile and the real profile.
The equations of the real profile are:
The equations of the real profile are:
X = X ( u ) − ε X ⋅ rb ;
Σ: (26)
Y = Y ( uX) −=
εY X
⋅ rb(,u ) − ε X ·rb ;
Σ: (26)
Y = Y ( u ) − ε ·r ,
Y b
where εX and εY represent the distances between the real and theoretical profiles measured
along the X and Y directions:

Y 
−X
εX = u
; εY = u
. (27)
 +X
Y  2 2  2 +X
Y 2
u u u u

For a certain value of the parameter u, Figures 6 and 7, the coordinates of the current
point M can be determined in the form:

X P = X ( u ) − ε X ⋅ rb ;
Machines 2023, 11, 518 10 of 21

where εX and εY represent the distances between the real and theoretical profiles measured
along the X and Y directions:
. .
Yu −Xu
εX = q ; εY = q . (27)
.2 .2 .2 .2
Yu + Xu Yu + Xu

For a certain value of the parameter u, Figures 6 and 7, the coordinates of the current
point M can be determined in the form:

Machines 2023, 11, x FOR PEER REVIEW X P = X ( u ) − ε X ·r b ; 11 of 23

M: (28)
YP = Y (u) − ε Y ·rb .

Machines 2023, 11, x FOR PEER REVIEW 12 of 23

Figure 6.
Figure 6. Reference systems
Reference usedused
systems to determine the primary
to determine peripheral
the primary surface ofsurface
peripheral the generating
of the
worm.
generating worm.

Figure 7.
Figure 7. Intermediate
Intermediatesurface approximation.
surface approximation.

If the
If the enwrapping
enwrappingcondition (24)(24)
condition is taken into into
is taken account, the coordinates
account, of the same
the coordinates of the same
point M can be determined at the moment when the “virtual pole”
point M can be determined at the moment when the “virtual pole” coincides coincides with thewith the
gearing pole,
gearing pole,therefore,
therefore,when
whenP belongs simultaneously
P belongs to theto
simultaneously three
the curves: the profile
three curves: thetoprofile to
be generated, the contact curve (CC) and the profile of the generating tool (S).
be generated, the contact curve (CC) and the profile of the generating tool (S).
The coordinates of the M point on the contact curve, in the fixed reference system,
are obtained from the absolute movement of the part (2), where φ is given by the Equation
(25):

xP = XP ⋅ cosϕ − YP ⋅ sinϕ;
MCC : (29)
y = X ⋅ sinϕ + Y ⋅ cosϕ.
Machines 2023, 11, 518 11 of 21

The coordinates of the M point on the contact curve, in the fixed reference system, are
obtained from the absolute movement of the part (2), where ϕ is given by the Equation (25):

x P = XP · cos ϕ − YP · sin ϕ;
MCC : (29)
y P = XP · sin ϕ + YP · cos ϕ.

When the parameter u takes values between the limits umin and umax , so that the
current point M describes the entire profile Σ, the contact curve, CC, is obtained in the form:

x (u) = X (u)· cos ϕ − Y (u)· sin ϕ;

CC : y(u) = X (u)· sin ϕ + Y (u)· cos ϕ; (30)
ϕ = ϕ ( u ).

Taking into account the absolute movement of the tool (3), and the coordinates of
the current point M in the fixed reference system, the coordinates of the same point are
obtained in the reference system associated with the rack gear tool:

ξ P = x P + Rrp ;
Mξη : (31)
ηP = y P + Rrp · ϕ.

As in the case of determining the contact curve (30), the parameter u is assigned
a variation between the limits umin and umax , obtaining the equations of the generating
tool profile:
ξ (u) = x (u) + Rrp ;
S : η (u) = y(u) + Rrp · ϕ; (32)
ϕ = ϕ ( u ).
Note: It is worth emphasizing that the profile was determined without the need to
write the relative movements between the tool and the blank. Of course, the influence of
these movements is not canceled, but the “virtual pole” method allows avoiding the need
to write the respective movements.
The intermediate surface will be the surface generated by the rack gear profile during
the main movement performed by the tool.
Considering that the main movement, when generating with the rack gear tool, is
an alternative rectilinear movement, having the direction parallel to the direction of the
surface to be generated, in the case of processing the cycloidal disk, the intermediate surface
will have as a generator the planar curve S, represented by the profile of the tool, and as
directories, the ζ axis, Figure 6.
Therefore, the equations of the intermediate surface are:

ξ (u, t) = x (u) + Rrp ;

η (u, t) = y(u) + Rrp · ϕ;
SI : (33)
ζ (u, t) = t;
ϕ = ϕ ( u ),

where t represents an independent variable parameter.

3.5. Determination of the Hob Mill Primary Peripheral Surface

The primary peripheral surface of the generator worm is a cylindrical helical surface
of constant pitch and is reciprocally enwrapping with the intermediate surface, SI.
To determine the primary peripheral surface of the screw, it is necessary to determine
the characteristic curve, the contact curve between the intermediate surface and the helical
surface of the worm.
For this purpose, four reference systems will be used, Figure 6:
- ξηζ is the reference system joined with the rack gear, with the origin in O1 , system in
which the intermediate surface is defined;
Machines 2023, 11, 518 12 of 21

- x0 y0 z0 —the mobile reference system, having the axes parallel to those of the ξηζ
system and the origin O2 displaced towards to it by the value Rrh , along the x0 axis;
O1 O2 = Rrh , where Rrh represents the rolling radius of the hob tool, constructive size;
→
- x1 y1 z1 —the mobile reference system, having the y1 axis parallel to the V axis of the
helical surface of the hob and the x1 axis superimposed on the x0 axis;
- ξ 1 η 1 ζ 1 —the reference system joined with the hob tool, having the η 1 axis superim-
→
posed on the axis of the hob, V.
In Figure 6, θ angle represents the angle by which the axis of the worm is rotated
towards to the η 1 axis, the η 1 axis being parallel to the η axis. This angle represents the
rotation angle around the x1 axis.
The coordinate transformation is defined between the ξηζ and x0 y0 z0 coordinate systems:
 
− Rrh
x0 = ξ + B, B =  0  (34)
0

or, developed:
     
x0 ξ − Rrh
 y0  =  η  −  0 . (35)
z0 ζ 0
In Equation (34), B represents the position vector of the origin of the system ξηζ in the
reference system x0 y0 z0 .
The distance between the origins of the XYZ and x0 y0 z0 reference systems is given by
the relation:
OO2 = Rrp + Rrh . (36)
According to the intermediate surface method, resulting from the Nikolaev theorem:
“The characteristic curve of a cylindrical surface, reciprocally enwrapping with a cylindrical
helical surface of constant pitch, is the geometric locus of the points where the normal to
the cylindrical surface intersects the axis of the helical surface.” [22,29].
The generator S of the intermediate surface SI is discretely known in the form:
 
ξ1 η1
 .. .. 
. . 
 
S=
 ξi ηi  . (37)
. .. 
 .. . 
ξn ηn

The intermediate surface SI will be approximated with a surface family of the plane
stripe type, determined by displacing the segments ξ i η i along a direction parallel with the
ζ axis, Figure 7.
In this way, the intermediate surface can be approximated by a cloud of points known
in discrete form:
ξ = ξ i + u1 · cos αi ;
SIa : η = ηi + u1 · sin αi ; (38)
ζ = hi ,
where SIa represents the intermediate surface approximated by the point cloud known in
discrete form, and u1 and hi are independent variable parameters.
In Equation (38), αi represents the inclination angle of the segment that approximates
the profile of the rack gear tool and is determined with the relation:

− ηi
 
η
αi = arctan i+1 . (39)
ξ i +1 − ξ i
Machines 2023, 11, 518 13 of 21

The normal to the approximate surface, taken to any of its known points, will have
the form:
→ ξ = ξ i + u1 · sin αi ;
N : η = ηi − u1 · cos αi ; (40)
ζ = hi .
→
At the same time, the V axis of the helical surface, in the ξηζ system, has the form:

→ ξ = − Rrh ;
V: η = t· cos θ; (41)
ζ = −t· sin θ,

with t independent parameter and θ the inclination angle of the hob curl.
The value of the θ angle results from the relation:
pm
tan θ = , (42)
2·π · Rrh

where pm represents the axial pitch of the helical surface.

The pitch of the helical surface can be calculated using the Equation:

2·π · Rrp
pm = , (43)
n
n being the number of the cam lobes.
From Equations (40) and (41), the coordinates of the intersection point between the
→ →
normal to the approximate intermediate surface, N and the axis of the helical surface, V,
can be determined:
→ → ξ = ξ i + u1 · sin αi = − Rrh ;
N ∩ V : η = ηi − u1 · cos αi = t· cos θ; (44)
ζ = h = −t· sin θ.
From Equation (44) results:

− Rrh − ξ i
   
R + ξi 1 R + ξi
u1 = ⇒ t = ηi + rh · ⇒ hi = − ηi + rh · tan θ. (45)
sin αi tan αi cos θ tan αi

Equation (45) allows determining the coordinates of a characteristic point, meaning a

contact point between the approximate cylindrical surface and the helical surface PC , in
the form:
ξ = ξi;
PC : η = ηi ; (46)
ζ = hi .
When i = 1 ÷ n, the characteristic curve in discrete form, CCm , is determined:
 
ξ1 η1 ζ 1
 .. .. .. 
. . .
 
CCm = 
 ξi ηi ζ i . (47)
. .. .. 
 .. . .
ξn ηn ζ n

In order to determine the primary peripheral surface of the worm tool, it is necessary
that this characteristic curve to be expressed in the x1 y1 z1 reference system and given a
→ pm
helical movement of V axis and helical parameter pe , pe = 2· π , in the ξ 1 η 1 ζ 1 system.
Machines 2023, 11, 518 14 of 21

The coordinate transformation from the ξηζ reference system to the x1 y1 z1 reference
system is obtained by passing through the transformation (34), then:

x1 = ω1 (θ )· x0 , (48)
 
1 0 0
where ω1 (θ ) = 0 cos θ sin θ .
0 − sin θ cos θ
→
The helical movement of V axis the helical parameter pe is:

ξ 1 = ω2T ( ϕ1 )· x1 + C, (49)

where ϕ1 represents the rotation angle of the reference system x1 y1 z1 , towards to the refer-
   
cos ϕ1 0 sin ϕ1 0
ence system ξ 1 η 1 ζ 1 , see Figure 6, ω2T ( ϕ1 ) =  0 1 0  and C =  pe · ϕ1 ..
− sin ϕ1 0 cos ϕ1 0
Therefore, the equation of the primary peripheral surface of the hob tool can be written:
 
− Rrh
ξ 1 = ω2T ( ϕ1 )·ω1 (θ )·[ξ + B] + C, B =  0 , (50)
0

or, developed,

ξ 1 = (ξ − Rrh )· cos ϕ1 − (η · sin θ − ζ · cos θ )· sin ϕ1 ;

SM : η1 = η · cos θ + ζ · sin θ + pe · ϕ1 ; (51)
ζ 1 = −(ξ − Rrh )· sin ϕ1 − (η · sin θ − ζ · cos θ )· cos ϕ1 .

By equalizing ζ 1 = 0, the value of the ϕ1 parameter is obtained, for which the points
on the SM surface also belong to the axial section:

η · sin θ − ζ · cos θ
−(ξ − Rrh )· sin ϕ1 − (η · sin θ − ζ · cos θ )· cos ϕ1 = 0 ⇒ tan ϕ1 = , (52)
Rrh − ξ
so:
η · sin θ − ζ · cos θ
 
ϕ1 = arctan . (53)
Rrh − ξ
Therefore, the axial section of the primary peripheral surface of the hob mill tool is
obtained, in the form:

ξ 1 = (ξ − Rrh )· cos ϕ1 − (η · sin θ − ζ · cos θ )· sin ϕ1 ;

η1 = η · cos θ + ζ · sin θ + p· ϕ1 ;
SA : ζ 1 = −(ξ − Rrh )· sin ϕ1 − (η · sin θ − ζ · cos θ )· cos ϕ1 ; (54)
η · sin θ −ζ · cos θ
ϕ1 = arctan Rrh −ξ .

4. Numerical Application for Profiling the Hob Mill for Processing the Disk of a
Cycloidal Reducer
A numerical application was made for the profiled disk of a cycloidal reducer. The
disk has the dimensions shown in Table 1, with the following notations: R—radius of the
base; r—radius of the roulette; a—the distance between the generating point of the cycloid
and the center of the roulette; rb —radius of the bolts; Rrp —rolling radius of the blank;
Rhr —rotation radius of the worm (value chosen constructively).
Machines 2023, 11, 518 15 of 21

Table 1. The dimensions of the profiled disk from the structure of the cycloidal reducer.
Machines 2023, 11, x FOR PEER REVIEW 17 of 23
R [mm] r [mm] a [mm] rb [mm] Rrp [mm] Rrh [mm]
36 4 2 5 40 60

The calculation application was made in the Octave program, a software product de-
The calculation application was made in the Octave program, a software product
signed to realize numerical calculations, in general for solving systems of equations with
designed to realize numerical calculations, in general for solving systems of equations with
linear algebra operations on vectors and matrices.
linear algebra operations on vectors and matrices.
By running the calculation program, the theoretical profile of the cycloid, the curve
By running the calculation program, the theoretical profile of the cycloid, the curve
equidistant to this profile and the profile of the generating rack gear tool were obtained,
equidistant to this profile and the profile of the generating rack gear tool were obtained, Figure 8.
Figure 8.

Figure8.8.Theoretical
Figure Theoreticalcycloid,
cycloid,equidistance
equidistanceatatit,it,contact
contactcurve
curveand
andthe
theprofile
profileofofthe
therack
rackgear
geartool.
tool.

The
Theenwrapping
enwrapping condition
condition will have
have the
thespecific
specificformformgiven
givenbyby the
the Equation
Equation (24).
(24). To
To solve this equation, the “fzero” function from the Octave program is used
solve this equation, the “fzero” function from the Octave program is used [30]. This func- [30]. This
function allows
tion allows finding
finding the the solution
solution of equation
of an an equation of f =(u)
of f(u) = 0 type.
0 type.
Table
Table22shows
showsthe
thecoordinates
coordinatesofofthe
thepoints
pointsbelonging
belongingtotothe theprofile
profiletotobe
begenerated
generated
and
and the coordinates of the points belonging to the profile of the generator rack geartool.
the coordinates of the points belonging to the profile of the generator rack gear tool.
Table 2. The coordinates of the points belonging to the profile to be generated and the profile of the
generating rack gear tool.

Enwrapping
Crt. No. u [rad] X [mm] Y [mm] ξ [mm] η [mm]
Condition
1 0.000 37.000 0.000 −3.000 0.000 0.000
2 0.873 36.298 3.671 −3.528 4.120 0.000
3 1.745 34.669 6.397 −4.819 7.607 0.000
4 2.618 32.569 8.689 −6.384 10.895 4.97 × 10−14
5 3.141 31.010 11.287 −7.000 13.963 −2.85 × 10−14
6 3.665 30.534 14.279 −6.384 17.030 6.39 × 10−14
7 4.538 30.670 17.384 −4.819 20.318 8.53 × 10−14
8 5.410 30.166 20.520 −3.528 23.805 −1.71 × 10−13
9 6.283 28.343 23.783 −3.000 27.925 1.95 × 10−13

To demonstrate the accuracy of identifying the solution for the enwrapping condition,
in the same table, for each value of the variable u, the value of this condition is given, found
using the ”fzero” function.
 9 6.283 28.343 23.783 −3.000 27.925 1.95·×

To demonstrate the accuracy of identifying the solution for the enwrapping

Machines 2023, 11, 518
tion, in the same table, for each value of the variable u, the value of this16condition of 21
i
found using the ”fzero” function.
Applying the algorithm described in Section 3.5, the primary peripheral su
the hob mill the
Applying toolalgorithm
is identified.
described in Section 3.5, the primary peripheral surface of the
hob mill tool is identified.
In Figure 9, the intermediate surface of the generating rack gear tool, the p
In Figure 9, the intermediate surface of the generating rack gear tool, the primary
peripheral surface of the hob and the characteristic curve are represented, and in
peripheral surface of the hob and the characteristic curve are represented, and in Table 3
the coordinates
the coordinates of some
of some of theofpoints
the points belonging
belonging to the characteristic
to the characteristic curve and thecurve
axial and t
section
section ofof the
the hobhob are presented.
are presented.

Figure 9.9.The
Figure Theintermediate surface,
intermediate the primary
surface, peripheralperipheral
the primary surface and surface
the characteristic
and thecurve.
characteristic cu

Table 3. The coordinates of the points on the characteristic curve and the axial section.
Table 3. The coordinates of the points on the characteristic curve and the axial section.
Characteristic Curve Axial Section
Crt. No. Characteristic Curve Axial Section
Crt. No. ξ 1 [mm] η1 [mm] ζ 1 [mm] ξ 1 [mm] η1 [mm] ζ 1 [mm]
1
ξ 1 [mm]
−53.000
η
0.010
1 [mm]
0.109
ζ1 [mm]
−53.000
ξ1 [mm]
0.001
η0.000
1 [mm] ζ1
21 −53.000
−53.528 4.175 0.010 0.437 0.109
−53.530 −53.000
4.139 0.001
0.000 0
32 −53.528 7.690 4.175 0.592 0.437
−54.820 −54.823 −53.530
7.642 4.139
0.000 0
43 −54.820 10.883 7.690 −0.616 0.592
−56.384 −56.387 −54.823
10.932 7.642
0.000 0
54 −56.384 13.77210.883−2.765 −0.616
−57.000 −57.067 −56.387
13.987 10.932
0.000 0
65 −57.000 16.68313.772−4.659 −2.765
−56.384 −56.576 −57.067
17.049 13.987
0.000 0
76 −56.384 19.91616.683−5.425 −4.659
−54.820 −55.087 −56.576
20.354 17.049
0.000 0
87 −54.820 23.43919.916−5.176 −5.425
−53.528 −53.778 −55.087
23.867 20.354
0.000 0
98 −53.528 26.74623.439−4.903 −5.176
−53.022 −53.248 −53.778
27.156 23.867
0.000 0

If the contact curve between the active surface of the cycloidal disk and the interme-
diate surface is denoted by L1 (Figure 8) and the contact curve between the intermediate
surface and the primary peripheral surface of the hob tool is denoted by L2 (Figure 9), the
intersection point of the two curves represents the characteristic point, meaning the contact
point between the cylindrical surface of the cycloidal disk and the primary peripheral
surface of the worm tool.
The axial section of the generating hob, obtained by applying the Equation (54), is
shown in Figure 10.
 diate surface is denoted by L1 (Figure 8) and the contact curve between the intermediate
surface and the primary peripheral surface of the hob tool is denoted by L2 (Figure 9), the
intersection point of the two curves represents the characteristic point, meaning the con-
tact point between the cylindrical surface of the cycloidal disk and the primary peripheral
surface of the worm tool.
Machines 2023, 11, 518 17 of 21
The axial section of the generating hob, obtained by applying the Equation (54), is
shown in Figure 10.

Figure10.
Figure 10. The
The intermediate
intermediate surface,
surface, the
the primary
primaryperipheral
peripheralsurface,
surface,and
andthe
thecharacteristic
characteristiccurve.
curve.

5.
5. Analysis
Analysis ofof the
the Results
Results
The
The profile of the cycloidal
profile of the cycloidaldisc
discwas
was determined
determinedby byassigning
assigningthe variableuuvalues
thevariable values inin
the range 0 ÷ 2π. For each value, the X, Y coordinates were calculated, using equations
the range 0 ÷ 2·π. For each value, the X, Y coordinates were calculated, using equations (28).
(28).To determine the enwrapping condition, the values of the variable ϕ were determined
which, Totogether
determine withthethe corresponding
enwrapping u value,
condition, the determines a value
values of the close
variable to 0 of
φ were the
deter-
function
mined which, together with the corresponding u value, determines a value close to 0the
(28). Thus, the pairs of independent variables (u, ϕ) that determine points on of
contact curve(28).
the function wereThus,
determined.
the pairs of independent variables (u, φ) that determine points on
As mentioned
the contact curve werein Section 2, the determination of the values of the variable ϕ was done
determined.
using the function “fzero”, which returns the point where the objective function has a value
As mentioned in Section Two, the determination of the values of the variable φ was
close to zero, as well as the value of the objective function at that point.
done using the function “fzero”, which returns the point where the objective function has
Given that for a point located exactly on the contact curve, the value of the objective
a value close to zero, as well as the value of the objective function at that point.
function (of the wrapping condition) is zero, non-zero values of this function can be
Given that for a point located exactly on the contact curve, the value of the objective
regarded as contact curve determination errors.
function (of the wrapping condition) is zero, non-zero values of this function can be re-
As can be noted in Table 2, where the values of the winding condition are presented,
garded as contact curve determination errors.
these errors are sufficiently small, having values below 2 × 10−13 mm. We consider that
As can be noted in Table 2, where the values of the winding condition are presented,
these errors are small enough to be negligible in practice.
these errors are sufficiently small, having values below 2 ×·10−13 mm. We consider that
Another approximation used within this algorithm is the one using the intermediate
these errors are small enough to be negligible in practice.
surface in discrete form, presented in the form (37).
Another approximation used within this algorithm is the one using the intermediate
Through this approximation, the plane curve that represents the generator of the
surface in discrete
intermediate surface form, presented
is replaced by ainset
the
ofform (37). whose extremities are located on that
segments
curve. Through this approximation, the plane curve that represents the generator of the in-
termediate surface
The greater theisnumber
replaced ofby a set of by
segments segments whose
which the extremitiessurface
intermediate are located on that
generator is
curve.
replaced, the better its approximation will be.
The greater the number of segments by which the intermediate surface generator is
replaced,
6. the better its approximation will be.
Conclusions
In the paper, the profiling of the hob mill tool designed to generate the active sur-
6. Conclusions
face of the cam of a cycloidal reducer was presented. The algorithm was based on the
In the paper,
determination the
of an profiling of surface,
intermediate the hob mill tool designed
belonging to generate
to the generating thegear,
rack activewhich
surface
is
of the cam ofenwrapping
reciprocally a cycloidal reducer was presented.
to the surface The algorithm
of the cycloidal disk, the was basedalgorithm
profiling on the determi-
using
nation
the of an intermediate
advantages surface,
of the “virtual pole”belonging
method. to the generating rack gear, which is recipro-
callyThe
enwrapping
proposed to the surface
algorithm usesofthe
the cycloidal disk,
intermediate the method
surface profilingwhich
algorithm using
involves the
deter-
advantages
mining of the “virtual
the characteristic pole”
curve onmethod.
a helical surface, mutually wrapping with a surface with
radial symmetry.
In the analysed case, the helical surface is the primary peripheral surface of the hob
mill, and the radially symmetrical surface is the active surface of the cycloidal disk.
The contact is studied on an intermediate surface that can be viewed, from a generation
point of view, as the primary peripheral surface of a virtual rack tool, profiled to generate
the target surface (the active surface of the cycloidal disc).
By the “virtual pole” method, the analytical form of the enwrapping condition is
determined. Since the analytical form of the system of Equation (30) leads to transcendental
equations, it is necessary to solve it numerically, using the mathematical facilities of the
Octave program.
Machines 2023, 11, 518 18 of 21

The numerical solution inevitably introduces an inaccuracy, but this is small enough
to be negligible. The level of errors, for each of the points where the winding condition is
calculated, is presented in the last column of Table 2, it can be noted that the maximum
error is 1.95 × 10−13 mm.
After determining the intermediate surface, it is used to establish the characteristic
curve, known as the contact curve between a cylindrical surface and a helical surface.
Normally, the determination of this curve is also particularly difficult, however, mak-
ing the observation that for each point of the curve two of the coordinates are known,
the coordinates ξ and η on the intermediate surface, all that remains is to determine the
coordinate ζ that satisfies the system of Equation (44).
In this way, the characteristic curve is determined in the form of a cloud of points, a
practically usable form for making the desired tool.
By using the virtual pole method in the step of determining the intermediate surface,
the need to find analytical equations describing the relative motion between this surface
and the surface to be generated was eliminated.
Since relative motion leads to complicated equations specific to each shape of the
surface to be generated, avoiding writing them greatly simplifies the computational effort
and eliminates a possible source of error introduced during the tool design stage.
The aim of the work was to demonstrate the possibility of practical application of the
virtual pole method to the design of hob mill tools and the numerical applications made in
Octave and CATIA demonstrate this.
Thus, the analytical equations of the cycloidal profile were known and the profiling of
the hob mill tool was realized. The intermediate surface was approximated with a family
of surfaces of plane stripe types, which were determined by approximating the generating
curve with a cloud of points known in discrete form.
At the same time, numerical applications were made, in the Octave and CATIA pro-
grams, for profiling of the worm tool designed for processing the active surface of the cam
of a cycloidal reducer, reaching the conclusion that the calculation time for tools profiling is
thus significantly reduced. The given disadvantage of the resulting error is small enough
to be technically acceptable and is fully compensated by this reduction in calculation time,
the resulting error coming from replacing the intermediate surface with an approximate
surface by strips (the normal being a curve, and it was approximated by a line segment).

Author Contributions: Conceptualization, V.G.T.; methodology, V.G.T. and N.B.; validation, N.B.,
V.G.T. and G.-A.M.; formal analysis, V.G.T. and N.B.; investigation, G.-A.M.; resources, V.G.T., G.-A.M.
and N.B.; writing—original draft preparation, G.-A.M.; writing—review and editing, G.-A.M.; vi-
sualization, N.B. and V.G.T.; supervision, V.G.T.; project administration, V.G.T. and N.B.; funding
acquisition, V.G.T. All authors have read and agreed to the published version of the manuscript.
Funding: This research received no external funding.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.
Machines 2023, 11, 518 19 of 21

Abbreviations
xy fixed reference system
XY initial position of the mobile reference system joint with the part
coordinates of M point in the mobile reference system joint with the part,
XP Y P
when the normal passes through the gearing pole
coordinates of M point in the fixed reference system,
xP yP
when the normal passes through the gearing pole
ξη initial position of the mobile reference system joint with the tool
ξ i, η i coordinates of a point discreetly know on the rack gear profile
Pv virtual pole
P gearing pole
new position of the mobile reference system joint with the part after
X0 Y0
it has been moved in order for Pv to take the position of P
new position of the mobile reference system joint with the tool after
ξ 0 η0
it has been moved in order for Pv to take the position of P
C1 centrode associated with the part
C2 centrode associated with the tool
Σ profile to be generated
ΣT theoretical profile which is equidistant with the profile to be generated, Σ
O origin of the mobile reference system of the part
O1 origin of the mobile reference system of the tool
origin of the mobile reference system of the tool after
O0 1
it has been moved in order for Pv to take the position of P
→ normal at the Σ profile
N Pv (vector that has the origin in the current point and the peak in virtual pole, Pv )
MC current point; point on the Σ profile
MT point on the tool profile
M point which describes the cycloidal profile
S profile of the tool
CC contact curve
CCm characteristic curve
A1 axode of the tool
A2 axode of the gear rack
Rrp rolling radius of the blank
Rrs rolling radius of the tool
Rrh rolling radius of the hob
ϕ rotation angle of the reference system associated with the profile to be generated
λ translation of the reference system joined with the rack gear tool
ω3T rotation matrix
A translation matrix
B translation matrix
C translation matrix
r radius of the roulette
→
r Pv position vector of the point Pv
rb radius of the bolt
R radius of the base
a distance between the generating point of the cycloid and the center of the roulette
u variable parameter which describes the part profile
u1 variable parameter which describes the discrete form of profile
v rotational parameter of the X2 Y2 reference system
v1 rotational parameter corresponding to the discrete form of the profile
i transmission ratio
→
δ parameter which describes N Pv
εX distance between the actual and theoretical profiles measured along the X direction
εY distance between the actual and theoretical profiles measured along the Y direction
t independent parameter
→
V axis of the helix
Machines 2023, 11, 518 20 of 21

θ helix angle of the hob curl

pm axial pitch of the helix
pe helical parameter
PC contact point between the approximate cylindrical surface and the helix
n number of lobes from the cycloidal disk
αi inclination angle of the segment that approximate the rack gear profile

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