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Karagiannis, Ioannis. "Tribo-dynamic analysis of hypoid gears in automotive differentials." Thesis, Loughborough University, 2013. https://dspace.lboro.ac.uk/2134/12801.
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Torsional vibrations in differentials of Rear Wheel Drive vehicles are of major importance for the automotive industry. Hypoid transmissions, forming the motion transfer mechanism from the driveshaft to the wheels, suffer from severe vibration issues. The latter are attributed to improper mesh between the mating gear flanks due to misalignments, variation of contact load and shifting of the effective mesh position. For certain operating conditions, the gear pair exhibits high amplitude motions accompanied with separation of the mating surfaces. Ultimately, single or even double-sided vibro-impact phenomena evolve, which have been related to noise generation. This thesis attempts to address these issues by effectively analysing the dynamic behaviour of a hypoid gear pair under torsional motion. The case study considered is focused on a commercial light truck. The major difference of the employed mathematical model to prior formulations is the usage of an alternative expression for the dynamic transmission error so that the variation of contact radii and transmission error can be accounted for. This approach combined to a correlation of the resistive torque in terms of the angular velocity of the differential enables the achievement of steady state, stable periodic solutions. The dynamic complexity of systems with gears necessitates the identification of the various response regimes. A solution continuation method (software AUTO) is employed to determine the stable/unstable branches over the operating range of the differential. The ensuing parametric studies convey the importance of the main system parameters on the dynamic behaviour of the transmission yielding crucial design guidelines. A tribo-dynamic investigation aims at expanding the dynamic model from pure dry conditions to a more integrated elastohydrodynamic (EHL) approach. Analytical and extrapolated solutions are applied for the derivation of the film thickness magnitude based on the kinematic and loading characteristics of the dynamic model. The temperature rise is governed mainly by conduction due to the thin lubricant films. The generated friction is also computed as a function of the viscous shear and asperity interactions. The effective lubricant viscosity is greatly affected by the pressure increase due to the resonant behaviour of the contact load. The final part of this work is involved with a feasibility study concerning the application of Nonlinear Energy Sinks (NES) as vibration absorbers, exploiting their ability for broadband frequency interaction. Response regimes associated with effective energy absorption are identified and encouraging results are obtained, showing the potential of the method.
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Hotait, Mohammad Adel. "A Theoretical and Experimental Investigation on Bending Strength and Fatigue Life of Spiral Bevel and Hypoid Gears." The Ohio State University, 2011. http://rave.ohiolink.edu/etdc/view?acc_num=osu1296853688.
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Fontana, Douglas. "Controle de vida da ferramenta do tipo lamina alternada Gleason no fresamento de coroas hipoidais." [s.n.], 2003. http://repositorio.unicamp.br/jspui/handle/REPOSIP/265597.
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Orientador: Anselmo Eduardo Diniz<br>Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica<br>Made available in DSpace on 2018-08-03T20:42:19Z (GMT). No. of bitstreams: 1
Fontana_Douglas_M.pdf: 10116872 bytes, checksum: 3a8e7469b54d02c31d22b732a5021bb1 (MD5)
Previous issue date: 2003<br>Resumo: A transmissão de movimentos mecânicos através de engrenagens é muito utilizado em todos os segmentos industriais.O corte de dentes de engrenagens é uma operação bastante importante dentro da usinagem. Apesar de sua importância, este é um processo pouco estudado, pois esta é uma área bastante restrita de atuação. Emfunção disso,a maior parte dos desenvolvimentos relacionados à tecnologia de corte de dentes de engrenagens ocorre no meio industrial, geralmente de forma empírica. A determinação do fim de vida das lâminas de corte Gleasonsão feitas,no chão de fabrica,pelos preparadores ou mesmo pelos operadores das máquinas.Tal decisão é baseada em critérios altamente subjetivos e portanto, faz com que o tempo de utilização da ferramenta apresente uma grande variabilidade,ou seja, em determinados momentos, a ferramenta é utilizada além de sua vida efetiva e, em outros momentos, esta utilização se dá a quém da mesma. Caso a ferramenta ultrapasse sua utilização ótima, ocorrem vários problemas, dentre os quais: maior volume de material retirado na afiacão da ferramenta com conseqüente redução do númerode vidas desta, a rugosidademédia (Ra) das peças toma-se muito elevada,fazendo com que a japidação do dentado (operação posterior ao corte) seja muito demorada e portanto, anti-econômica.Por outro lado, se a ferramenta for sub-utilizada. ocorre um desperdício de lâmina,bem como um aumento do tempo de processamento pois um maior número de trocas da ferramenta vai ocorrer. Este trabalho procurou estabelecer um parâmetro objetivo de fim de vida da lamina de corte do tipo Hardac, utilizandoo processo de corte denominado Completo (Completing). Para tanto, foi feito um trabalho junto a um fubricante de auto-peças, que usina engrenagens cônicas e hipoidais, utilizada em
diferenciais de caminhões e ônibus.O parâmetro escolhido foi a rugosidade média (Ra) do flancodos dentes das engrenagens. O comportamento e a dispersão da vida da ferramenta anterior e posterior à implantação do parâmetro proposto foram analisadas.Os resultados mostram uma maior uniformidade da vida das laminas de corte gleason,bem como dos tempos de afiação das mesmas e Iapidação do dentado. Além disso, as lâminas passaram a ser utilizadas de forma otimizadas em relação ao seu desgaste e à quantidades uperficial da peça. Um segundo objetivo do trabalho foi comparar a vida de ferramentas de aço rápido
com algumas coberturas diferentes e também sem cobertura na superficie de saída, pois foram utilizadas após a afiação da ferramenta com cobertura total Pelo desempenho mostrado nos resultados a melhor cobertura foi aquela de nitreto de titânio originária do fabricante da ferramenta e do equipamento<br>Abstract: The transmission of mechanical motion through gears is very used in alI industrial segments.The cutting process of gears is a very important process in the manufacturing. Despiteits importance this is a process not so studied as it a very specific area. According to this, most part ofthe industrial field, usually in an empirical way. The determination to end the life of a Gleason Cutter Blade is made by machine operators. The decision is based on highly subjective criteria and as for this it makes the using time of this tool to presenta great variability. As resuh this tool is sometimes used longeror less than it should.If its use
is longer exceedingits life time,many problems may occur, such as: bigger volume taken from the sharpening material of tools which results in a reduction of their lifetime, the average rougbness (Ra) of the parts becomes higher which makes lapping of the teeth (process which occurs after cutting) to take longer and as a resuh not economical.On the other hand,if the tool is used less there is a waste ofthe blade as well as an increasein the manutacturing process due to the change of tools. This work tried to establishan objetive parameteron the end ofthe life ofthe Hardac type ofblade, using a cutting process called Completing.For this reason this work was done together with an Automotive Company that produces beveland hypoidgears used on heavyduty drive axles for trucks and buses. The chosen parameter was the average rougtmess(Ra) ofthe teeth flankof the gears. The behavior and dispersion of the tool Jife before and after the setting of the proposed
parameter were analized. The resuhs show a greater uniformity of the life the Gleason Cutter Blade as well as its sbarpeningtime and teeth lapping. Apart from it, the blades started to be used on an optimized way related to its wear and to the surlace quality of the piece. Another objetive of this work was to compare the high speed steel tool life with some different coats andalso no coating on theftont ceplane,as theywere used after the tool sharperning with total coat. For the result showed the best coating was the one with titanium nitrideoriginate dftom the tool and equipamentmanufacturer<br>Mestrado<br>Materiais e Processos de Fabricação<br>Mestre em Engenharia Mecânica
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Vogel, Olaf [Verfasser]. "Gear-Tooth-Flank and Gear-Tooth-Contact Analysis for Hypoid Gears : An Application of Singularity Theory / Olaf Vogel." Aachen : Shaker, 2007. http://d-nb.info/1170528155/34.
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Park, Daehyun. "Development of Surface Wear and Lapping Simulation Models for Hypoid Gears." The Ohio State University, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=osu1251739728.
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Erkilic, Erdem. "A Model to Predict Pocketing Power Losses in Spiral Bevel and Hypoid Gears." The Ohio State University, 2012. http://rave.ohiolink.edu/etdc/view?acc_num=osu1337616576.
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Vittal, Srigiripura Sahana. "Development of a method for estimation of contact fatigue life in hypoid gears." Thesis, KTH, Maskinkonstruktion (Inst.), 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-288898.
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Hypoid gears have been used extensively in automobiles, aerospace, marine and other applications for decades. The special advantages of hypoid gears come with inherent contact complexities of varying curvature and sliding in both profile and lengthwise direction. Spalling failure is catastrophic and needs to be addressed with deeper roots in gear design. Analytical methods present several limitations. Iterative development from experimentation is expensive and time consuming with different nonlinear parameters difficult to interpret. This thesis aims to develop a method to calculate contact fatigue life for initiation of spalling using finite element methods. Experiments have played a major role in understanding the causal factors for failure, determining the fatigue life and to study the major system design parameters. A failure analysis of the fractured flank is performed. It clarified the design causal factors for failure and the mechanism of failure. Pinion being the vulnerable part is the focus of this thesis, a finite element model was developed on ANSOL HFM and the residual stresses were superposed on MSC Marc. A finite element fatigue analysis is performed on FEMFAT and the component fatigue life is determined. The calculated fatigue life is compared with physical testing results using Weibull statistical analysis in combination with probabilistic bearing life models to formulate emphatical correlation methods. The goal of this thesis is to establish a method to estimate fatigue life by taking up example of computing subsurface fatigue life of a hypoid pinion. The influence factors like the method of contact analysis, different types of residual stresses due to case hardening and shot peening, fatigue criteria, friction, material properties are studied in this thesis to develop a conscience for the methodology to computing contact fatigue life. The bulk material properties based on hardness represented fatigue properties more accurately. Scaled normal stress in critical plane fatigue criteria was found more suitable for contact analysis with pre-stresses and multi-axial non-proportional contact stress state on FEMFAT. Finite element based contact analysis method was found to be more suitable for subsurface fatigue life estimation despite the inherent advantages of the hybrid surface integral method and its accurate representation of friction. It was found that inclusion of friction in model did not change the fatigue life significantly, showing that the influence of hardness, surface topographies lubrication and contact temperature on shear stresses are too large to be neglected. Contact fatigue life increased by a factor of 4.4 times due to shot peening of gears in comparison with case hardening indicating the influence of residual stresses. For the estimation of fatigue life at the initiation of failure, a complete correlation with the fatigue test results could not be achieved and reasons for deviations were clearly identified. The area of damage indicated by this computation method correlated with the damage observed during tests. The observations and calculations indicated premature failure of pinion with explanation of mechanism of failure of pinion flank using contact conditions.<br>Hypoidväxlar har använts i stor utsträckning i bilar, flyg-, marin- och andra applikationer under årtionden. De speciella fördelarna med hypoidväxlar kommer med inneboende kontaktkomplexitet med varierande krökning och glidning i både profil och längdriktning. Spallingfel är katastrofala och måste hanteras med grundlig redskapsdesign. Analytiska metoder har flera begränsningar. Iterativ utveckling baserad på experiment är dyrt och tidskrävande med olika icke-linjära parametrar som är svåra att tolka. Denna avhandling syftar till att utveckla en metod för att beräkna kontaktutmattningslivslängden för initiering av spalling med finitaelementmetoden. Experiment har spelat en viktig roll för att förstå orsaksfaktorerna för fel, bestämma utmattningslivslängden och för att studera de viktigaste systemdesignparametrarna. En felanalys av den skadade kuggflanken utfördes, vilket förtydligade felens orsaksfaktorer och den underliggande felmekanismerna. Driften är fokus för denna avhandling, en finitaelementmodell utvecklades med ANSOL-HFM och restspänningarna överlagrades med FEM-verktyget MSC-Marc. En slutlig elementutmattningsanalys utfördes med FEMFAT och komponentens utmattningstid bestämdes. Den beräknade utmattningslivslängden korrelerades med fysiska provningsresultat genom att tillämpa statistisk Weibullanalys i kombination med probabilistiska livslängdsmodeller. Målet med denna avhandling är att utveckla en metod för att uppskatta utmattningslivslängden och att tillämpa metoden för att beräkna bulkmaterialets utmattningslivslängd för ett hypoidrev. Påverkningsfaktorer som metoden för kontaktanalys, olika typer av restspänningar på grund av ythärdning och kulblästring, utmattningskriterier, friktion, materialegenskaper studeras i denna avhandling för att utveckla denna metod för att prediktera kontaktutmattningslivslängden. Bulkmaterialegenskaperna för hårdhet representerade utmattningsegenskaperna mera exakt. Skalad normalspänning i kritiska planutmattningskriterier befanns vara mer lämplig för kontaktanalys med förspänningar och multi-axiell icke-proportionell kontaktspänningsstatu än andra egenskaper med FEMFAT. Metodbaserad kontaktanalysmetod visade sig vara mer lämplig för uppskattning av ytutmattningslivslängd trots de inneboende fördelarna med hybridytaintegralmetoden och dess mera exakta friktionsrepresentation. Det visade sig att inkludering av friktion i modellen inte markant förändrade livslängden, vilket visade att påverkan av hårdhet, smörjning av ytorna och kontakttemperatur på skjuvspänningarna är för stor för att försummas. Kontaktutmattningslivslängden ökade med en faktor 4,4 gånger på grund av kugghjulning jämfört med ythärdning, vilket indikerar restspänningspåverkan. För att uppskatta utmattningslivslängden vid inledningen av ytfel kunde en fullständig korrelation med utmattningstestresultaten inte uppnås och orsakerna till avvikelser identifierades tydligt. Det skadade område som indikeras av denna beräkningsmetod korrelerade väl med den skada som observerades under testerna. Observationerna och beräkningarna indikerade tidigt fel i kuggen med förklaring av mekanismen för fel hos kuggflanken med hjälp av aktuellt kontaktförhållande.
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Sugyarto, Eddy. "The Kinematic Study, Geometry Generation, and Load Distribution Analysis of Spiral Bevel and Hypoid Gears." The Ohio State University, 2002. http://rave.ohiolink.edu/etdc/view?acc_num=osu1392985391.
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Wang, Yawen. "Vibration and Sound Radiation Analysis of Vehicle Powertrain Systems with Right-Angle Geared Drive." University of Cincinnati / OhioLINK, 2017. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1491318542819425.
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Vaidyanathan, Sathyanarayanan. "Application of plate and shell models in the loaded tooth contact analysis of bevel and hypoid gears." The Ohio State University, 1993. http://rave.ohiolink.edu/etdc/view?acc_num=osu1335540802.
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Makam, Sandeep. "An Experimental Study on the Influence of Misalignments on the Static Transmission Error of Hypoid Gear Pairs." The Ohio State University, 2010. http://rave.ohiolink.edu/etdc/view?acc_num=osu1281992123.
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Kolivand, Mohsen. "DEVELOPMENT OF TOOTH CONTACT AND MECHANICAL EFFICIENCY MODELS FOR FACE-MILLED AND FACE-HOBBED HYPOID AND SPIRAL BEVEL GEARS." The Ohio State University, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=osu1245266082.
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Gill, Harnavpreet Singh. "Computationally Robust Algorithms for Hypoid Gear Cutting and Contact Line Determination using Ease-Off Methodology." The Ohio State University, 2020. http://rave.ohiolink.edu/etdc/view?acc_num=osu1587499768039312.
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Blettery, Hugo. "AN EXPERIMENTAL STUDY OF THE INFLUENCE OF MISALIGNMENTS ON THE LOADED TRANSMISSION ERROR AND ROOT STRESSES OF HYPOID GEAR PAIRS." The Ohio State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=osu1480621750810372.
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C, Gopalakrishnan Srikumar. "Tribodynamics of Right Angled Geared System." University of Cincinnati / OhioLINK, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1540566189193567.
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Padmanabhan, Maadhav. "Utveckla en FE-modell för att studera effekten av presspassning på en hypoid växelsats." Thesis, KTH, Maskinkonstruktion (Inst.), 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-225872.
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Gears are an integral part of devices ranging from simple wrist watches to complex systems like automotive and wave energy converters. They play a very important role in the transfer of torque. There are several types of gears to be chosen from, depending on the application. This thesis work deals exclusively with hypoid gears. A hypoid gear is a type of bevel gear, that transmits torque between two non-parallel shafts. It is similar to a spiral bevel gear, except that the pinion axis can be oset. It is this ability to offset, that renders hypoidgears as highly sought-after gears for automotive applications. It is crucial that these hypoid gears are designed efficiently and that their life before failure is predictable, to a reasonable degree of accuracy. To enable such predictions, this thesis makes an effort to build a finite element (FE) model. With the developed FE model, a study of the effect of press-fit on the ring gear's root bending stresses, that is present in a hypoid gear set of a car's Rear-Drive Unit (RDU), was carried out. The FE model was built on three different software - Transmission 3D (T3D), Hypoid Face Milled (HFM) and MSC Marc (Marc). The effect of press-fit on root bending stresses of the ring gear was first analyzed on T3D. To determine if the press-fit was correctly induced, the model was rebuilt and analyzed on Marc. HFM was used to determine the effect of inclusion of different components on the root bending stresses. Additionally,the HFM model was also replicated on Marc and a press-fit of 100m was induced. This was done to see if modelling the press-fit on HFM gave similar results to that of T3D and if using HFM in conjunction with Marclead to a better modelling procedure. It was found that the maximum root bending stresses increased linearly with increasing press-fit dimension. It was also found that the inclusion of different parts does not cause a significant increase in root bending stresses, except for the inclusion of differential cage. The effect of press-fit could not be quantified despite knowing that it affects the root bending stresses. When the same analysis done on HFM or T3D was done on Marc, there wasa 10% increase in stresses at highly stressed zone in Marc model of T3D; there was 10-15% increase in stresse sat highly stressed zone in the HFM model of Marc. Hence, quantification remained an impediment. It was not possible to quantify the error that occurred during the migration of analysis from HFM or T3D to Marc. However, potential causes of these errors could be the error in computation of bearing forces and difference in the definition of contacts in the software. Owing to large computational time and limited working period, all the analysis on Marc was carried out for one position and for the first time step of the gear mesh. If the errors in migration of analysis from one software to another could be quantified, then this modelling can be used to estimate the contribution of press-fit to rootbending stresses on the ring-gear. Although the contact pattern comparison between the virtual models andthe physical test suggests that HFM is a more trustworthy software, it is recommended to conduct some straingauge measurements on different ring gear teeth and then compare the results with those of the virtual model.<br>Kugghjul är en integrerad del av utrustningar som sträcker sig fråan enkla armbandsur till komplexa system som bilar eller vågfrakftverkomvandlare. De spelar en mycket viktig roll vid överföring av vridmoment. Det finns flera typer av kugghjul som man kan välja från, beroende på applikationen. Detta projekt handlar exklusivt om hypoidväaxlar. En hypoidväxel är en typ av vinkelväxel som överför vridmoment mellan två icke parallella axlar. Det liknar ett spiralformat växel, förutom att kugghjulets axel kan förskjutas. Det är denna förmåga att kompensera, vilket gör hypoidväxlar en mycket eftertraktade redskap för fordonsapplikationer. Det är avgörande att dessa hypoid-redskap är konstrueras effektivt och att deras liv före misslyckande ar förutsägbart, i en rimlig grad av noggrannhet. För att möjliggöra sådana Förutsägelser gör denna avhandling ett försök att bygga en finita-element (FE) modell. Med den utvecklade FE-modellen utfördes en studie av effekten av presspassning pa ringvaxelns rotböjspänningar, som finns i en hypoid växelsats av en bilens Bakre enhet (RDU). FE-modellen byggdes på tre olika programvaror: Transmission 3D (T3D), Hypoid Face Milled (HFM) och MSCMarc (Marc). Effekten av presspassning på riggböjspänningarna hos ringväxeln analyserades först på T3D. För att bestämma om presspassningen var korrekt inducerad, byggdes modellen och analyserades på Marc. HFM användes för att bestämma effekten av inkludering av olika komponenter på rotböjspänningarna. Dessutom replikerades HFM-modellen också på Marc och en presspassning på 100 microns inducerades. Detta gjordes för att se om modellering av presspass på HFM gav liknande resultat som T3D och om man använde HFM i kombination med Marc leder det till ett bättre modelleringsförfarande. Det visade sig att de maximala rotböjspänningarna ökade linjärt med ökande presspassningsdimension. Det konstaterades ocksåa att införandet av olika delar inte orsakar en signifikant ökning av rotböjspänningar, utom införandet av differentialbur. Effekten av presspassning kunde inte kvantifieras trots att man vet det påverkar rotböjspänningarna. När samma analys gjord på HFM eller T3D gjordes på Marc, fanns det en 10% ökning av späanningar vid starkt stressad zon i Marc-modellen av T3D; det var 10-15% ökning av spänningar vid starkt stressad zon i HFM-modellen av Marc. Därför förblev kvantifiering ett hinder. Det var inte möjligt att kvantifiera felet som inträffade under analysanalysen från HFM eller T3D till Marc. Dock kan potentiella orsaker till dessa fel vara felet vid beräkning av bärkrafter och skillnad i definitionen av kontakter i programvaran. På grund av stor beräkningstid och begränsad arbetstid utfördes all analys på Marc för bara en position och för det forsta steget av växelns nät. Om felen i migration av analys från en programvara till en annan kunde kvantifieras, då kan denna modellering användas för att beräkna bidragen från presspassning till rotböjspänningar på ringväxeln. Även om kontaktmönstersjämforelsen mellan de virtuella modellerna och det fysiska testet föreslår att HFM är en mer pålitlig programvara, rekommenderas det att utföra en viss belastning Mätmätningar på olika ringväxeltänder och sedan jämföra sedan resultaten med dem från virtuella modellen.
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Engdahl, Philip, and Jesper Aspelin. "Kvalitetssäkring av fläckanalys för hypoidväxlar." Thesis, Örebro universitet, Institutionen för naturvetenskap och teknik, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:oru:diva-85961.
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Det amerikanska företaget Meritor är en globalt ledande leverantör av lösningar för bland annat drivlinor, bromsning och rörlighet till både industri- och kommersiella fordon. Meritor HVS AB:s fabrik, belägen i Lindesberg, är främst inriktad på montering av kompletta hjulaxlar samt bearbetning av komponenter, inklusive kugghjul till hypoidväxlar, till tunga fordon såsom buss och lastbil. Hypoidväxlar används i bakaxlar då de klarar av höga vridmoment samtidigt som de har en hög hållbarhet och är relativt tysta i drift. Ett steg i monteringsprocessen för växlarna på Meritor är att passa in pinjong och kronhjul, två typer av kugghjul, så att de har god kontakt mellan kuggarna. En god kontaktyta behövs för att inte påverka kugghjulens livslängd samt säkerställa tyst drift. Kontaktytan verifieras bland annat genom okulär fläckanalys av montören. Syftet med examensarbetet var att utföra en undersökning om hur kvalitetssäkringen av fläckanalysen kan förbättras i Meritors centrumväxelmontering. Visionsystem är en metod som ansetts lämpad och extra intressant att undersöka. Under arbetet har nuläget kartlagts genom bland annat observationer, intervjuer och interna dokument såsom arbetsinstruktioner. Undersökning av kvalitetssäkringslösningar har utförts genom bland annat studiebesök. Fem stycken lösningsförslag har tagits fram varav en kombination av några av dem skulle ge en mer fullständig kvalitetssäkring. För att bestämma exakt vilken lösning som är mest lämpad så behövs en kravspecifikation tas fram vilket i sin tur kan kräva att flera olika tester behövs genomföras för att kartlägga behov och önskemål.<br>he American company Meritor is a globally leading provider of solutions for drivetrain, braking and mobility for both industrial and commercial vehicles. Meritor HVS AB's factory, located in Lindesberg, is primarily focused on the assembly of complete wheel axles and gears but also machining of components, including gears for hypoid gears, for heavy vehicles such as busses and trucks. Hypoid gears are used in rear axles as they can handle high torque while having a high durability as well as begin relatively quiet in operation. One step in the assembly process of the gears at Meritor is to fit the pinion and ring gears, two types of gears, so that they have good contact (mesh) between the gears. A good contact surface is necessary to not impact the life-span of the gears and to ensure quiet operation. The contact is verified through ocular contact spot analysis by the assembly worker, where the assessment may be a difficult task as well may differentiate between the assembly workers, which is a risk of false assessment. The aim of this project was to carry out a study regarding how quality assurance of the contact spot analysis can be done in Meritor's gear assembly. Vision systems are a method that is considered suitable and of extra interest to investigate. During the work, the current situation has been mapped through observations, interviews and internal documents such as operation instructions. Investigation of quality assurance solutions has been done through e.g. study visit. Five proposals for solutions have been developed where a combination of some of them would provide a more complete quality assurance. In order to determine exactly which solution that is most suited, a specification of requirements is needed to be determined. Several tests could be required to establish requirements and requests.
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Omasta, Milan. "Studium utváření elastohydrodynamických mazacích filmů u hypoidních převodů." Doctoral thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2013. http://www.nusl.cz/ntk/nusl-234175.
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This PhD thesis deals with elastohydrodynamic lubrication (EHL) under the conditions that occur between mated hypoid gear teeth. The aim is to describe experimentally the behaviour of lubricating film and mechanisms of its formation. The focus is mainly placed on clarifying the influence of direction and magnitude of sliding velocity in circular and elliptical contacts. Generally, it is still assumed that the direction of sliding velocity has no effect on the resulting lubricant film. In this study optical interferometry is used to determine distribution of lubricant film thickness. This work includes new and original results which clarify the studied problem. It was found that the direction of sliding velocity affects shape of the film at high speeds. This relates to the effect on heat flow through the contact. The results have an impact on the development of general EHL theory and provide knowledge applicable in film thickness prediction in the design of real tribological nodes.
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Ramachandran, Selvaraj. "Hypoid gear optimization." PDXScholar, 1992. https://pdxscholar.library.pdx.edu/open_access_etds/4419.
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A hypoid gear optimization procedure using the method of feasible directions has been developed. The objective is to reduce the gear set weight with bending strength, contact strength and facewidth-diametral pitch ratio as constraints. The objective function weight, is calculated from the geometric approximation of the volume of the gear and pinion. The design variables selected are number of gear teeth, diametral pitch, and facewidth. The input parameters for starting the initial design phase are power to be transmitted, speed, gear ratio, type of application, mounting condition, type of loading, and the material to be used. In the initial design phase, design parameters are selected or calculated using the standard available procedures. These selected values of design parameters are passed on to the optimization routine as starting points.
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Yang, Junyi. "Nonlinear Dynamics of Driveline Systems with Hypoid Gear Pair." University of Cincinnati / OhioLINK, 2012. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1336138173.
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Hua, Xia. "Hypoid and Spiral Bevel Gear Dynamics with Emphasis on Gear-Shaft-Bearing Structural Analysis." University of Cincinnati / OhioLINK, 2010. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1289944847.
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Peng, Tao. "Coupled Multi-body Dynamic and Vibration Analysis of Hypoid and Bevel Geared Rotor System." University of Cincinnati / OhioLINK, 2010. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1282931782.
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Klein, Alexander. "Spiral bevel and hypoid gear tooth cutting with coated carbide tools /." Aachen : Shaker, 2007. http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&doc_number=015866212&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA.
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Gregefors, Carl. "Correlation study between FEA and physical testing for a hypoid gear set." Thesis, KTH, Hållfasthetslära (Inst.), 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-190100.
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This thesis describes a correlation study of gear tooth bending stresses between physical testing and Finite Element modelling. It was conducted after a discovery at GKN that there were inconsistencies between the measured and calculated tooth root stresses for a hypoid gear set. The aim of the thesis was to investigate to what extent the stresses are correlated and if the program used is reliable for bending stress calculation. This would then be used to create S/N-curves for the gear set. The correlation was studied for several different aspects of the gear set. The contact pattern for the gear set was compared visually for a range of torque levels to see how well they matched and if this would contribute to the discrepancy. The root bending stress had been measured using a number of strain gauges in the root of the teeth. The location of these strain gauges was measured using a digital microscope and coordinate-measuring machine and the strain in the corresponding location in the Finite Element model was evaluated. The calculated contact pattern showed a slight under-approximation for lower torque levels but the agreement increased with increasing torque levels. The stress showed good correlation in the highly stressed middle area of the tooth for both the pinion and the ring gear while the lowly stressed heel and toe were worse. As the maximum stress is the deciding factor for bending fatigue the program was deemed reliable and the results used to evaluate fatigue life for the gear set.<br>Detta examensarbete beskriver en korrelationsstudie för böjspänningen i kuggrötter där finita element-simuleringar jämförs med fysiska testresultat. Korrelationsstudien utfördes då GKN upptäckte att det var inkonsekvent överensstämmelse mellan uppmätta och beräknade böjspänningar i kuggroten i en hypoidkuggväxel. Syftet var således att säkerställa till vilken grad spänningarna var korrelerade och om det program som använts är pålitligt vad gäller böjspänningsberäkningar. Ett flertal aspekter undersöktes i korrelationsstudien. En okulär jämförelse mellan det den beräknade och den uppmätta kontaktarean gjordes för ett intervall av momentnivåer för att fastställa hur väl de stämde och för att se om det kunde bidra till diskrepansen i spänningsjämförelsen. Böjspänningen mättes i testet med ett antal trådtöjningsgivare monterade i kuggroten. Dessa givares position mättes upp med hjälp av ett digitalt mikroskop och en koordinatmätningsmaskin. Samma spänning mättes sedan upp i motsvarande område i den finita element-modellen. Den uppmätta kontaktarean var något underskattad för låga momentnivåer men vid högre nivåer var korrelationen god. I områden med hög böjspänning i kuggroten var korrelationen mellan test och simulering god. I kuggtändernas tå och häl var korrelationen sämre. Då det intressanta området är det med hög spänning ansågs programmet var tillräckligt exakt för att användas för att skapa utmattningsdiagram från testdata.
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Klein, Alexander [Verfasser]. "Spiral Bevel and Hypoid Gear Tooth Cutting with Coated Carbide Tools / Alexander Klein." Aachen : Shaker, 2007. http://d-nb.info/1166510123/34.
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Shi, Zhenghong. "Nonlinear Time-varying Dynamic Modeling of Vehicle Driveline Systems with Emphasis on Hypoid Gear Excitation and Response." University of Cincinnati / OhioLINK, 2017. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1490355055106922.
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Fossier, Charlotte. "Investigations on the efficiency of truck axles and their hypoid gear set : A thermo-mechanical model." Thesis, Lyon, 2018. http://www.theses.fr/2018LYSEI019.
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Pour répondre au besoin des clients ainsi qu’aux réglementations gouvernementales, les constructeurs de camions doivent diminuer la consommation et les émissions de leurs véhicules. Une solution-clé est d’améliorer le rendement de la transmission du camion, dont le pont fait partie. Leur design n’a longtemps été optimisé qu’en fonction de critères de durabilité et de bruit. L’objectif de ce travail est donc de caractériser le rendement des ponts de camion. La dissipation de puissance au sein du pont est causée par l’engrènement, les roulements, les joints et le barbotage. Des méthodes permettent d’estimer globalement ces pertes de puissance, mais elles ne sont pas forcément adaptées aux ponts. En effet, l’élément principal du pont est un engrenage spiro-conique ou hypoïde et son importance est étudiée : sa forme influe sur le barbotage, tandis que sa géométrie de denture et sa cinématique gouvernent le frottement à l’engrènement. Il semble ainsi important d’évaluer le frottement de ces couples coniques par une approche locale et d’étudier l’influence des paramètres de denture. Cependant, les pertes de puissance dépendent de la température, via les propriétés de l’huile. Des expériences montrent un important écart de température entre les composants. Il faut donc considérer des températures locales plutôt qu’une température d’huile globale. Le rendement et la durabilité peuvent être impactés par des points chauds. La méthode des réseaux thermiques permet de modéliser les échanges thermiques du pont ainsi que la distribution de températures. Les tests classiques de rendement mesurent uniquement la perte globale et la température d’huile : rien ne permet de confirmer la répartition des pertes entre sources. Une campagne d’essais avec mesures de température est donc réalisée et valide le modèle pour le calcul des températures locales et pour l’estimation des pertes de chaque composant. Ce modèle peut alors être utilisé lors du design de futurs ponts<br>To fulfil customer demands, but also government regulations, the truck industry must decrease the fuel consumption and emissions of its vehicles. A key development is to improve the efficiency of the powertrain, which includes the axle. Until recently, optimisation of axle design has mainly concerned durability and noise aspects. The aim of this study is then to characterise the efficiency of truck axles. As for most of the mechanical transmissions, power dissipation in axles is due to gear mesh, rolling element bearings, seals and oil churning. Formulae already exist to estimate these power losses at a global level, but they are not always adapted to axles. Indeed, the main component of axles is a spiral bevel or a hypoid gear set. The influence of these special gears on efficiency is investigated here: their shape drives oil churning losses, while their tooth geometry and their kinematics impact friction at gear mesh. Therefore, the meshing friction of the gear set is also evaluated thanks to a local approach. The influence of some gear parameters is studied. However, power losses are influenced by temperature through oil viscosity. As previous experiments underline non-negligible temperature difference between components, it is necessary to consider local temperatures instead of a global oil temperature. Efficiency but also durability can be impacted by local hot spots. The thermal network method is used to model the thermal exchanges inside and outside the axle and to calculate temperature distribution. Usual efficiency tests on axles measure only global power loss and oil temperature: no evidence allows to confirm a power loss breakdown. Thus, a test campaign with temperature measurements is done and validates the model on local temperature calculation but also on estimation of component power losses. The model can be used at design stage for future development of axles
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Wang, Jun. "Nonlinear Time-varying Gear Mesh and Dynamic Analysis of Hypoid and Bevel Geared Rotor Systems." University of Cincinnati / OhioLINK, 2007. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1186604249.
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Xu, Hai. "Development of a generalized mechanical efficiency prediction methodology for gear pairs." Columbus, Ohio : Ohio State University, 2005. http://rave.ohiolink.edu/etdc/view?acc%5Fnum=osu1128372109.
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Wang, Yawen. "Torque Load Effect on Multi-Point Mesh and Dynamics of Right-angle Geared Drives." University of Cincinnati / OhioLINK, 2013. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1384870250.
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Eigner, Florian. "Untersuchungen am koaxialen Getriebe „HypoGear“." Technische Universität Chemnitz, 2019. https://monarch.qucosa.de/id/qucosa%3A34306.
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Auf der Suche nach immer kompakteren koaxialen Getrieben für kleine Antriebe steht eine neue Bauweise bereit. Der Foliensatz stellt kurz die Baugruppen eines solchen Getriebes vor und klärt über einige der Herausforderungen auf, die die Entwicklung beeinflussen. Weiterhin wird auf die Berechnung der verbauten Hypoidzahnradstufe eingegangen. Die Berechnung der Zahngeometrie ausgehend von den Wälz-Gleit-Körpern wird losgelöst von den Einschränkungen betrachtet, die herkömmliche Serienfertigungsverfahren mit sich bringen. Ausblickend werden die Entwicklungsschritte umrissen, die zunächst zum Prototyp und darüber hinaus zur Serienreife führen.
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Koronias, George. "Elastomultibody dynamics of RWD axle whine phenomena." Thesis, Loughborough University, 2012. https://dspace.lboro.ac.uk/2134/9721.
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Automotive industry is faced with numerous power train Noise, Vibration and Harshness issues. Particularly, in the driveline area of vehicles a noise commonly referred as differential axle whine which is a tonal response and becomes apparent under cruising conditions. This is one of the key concerns in rear wheel drive commercial vehicles. Although not a failure state, it is regarded as a quality issue and a source of annoyance, which can lead to warranty concerns. The associated cost of palliation to Ford Motor Company was estimated to be $25,000,000 in 2003. There have been several ways of studying axle whine through experimentation and numerical analysis. In this thesis, a new approach for investigating axle whine is highlighted, which is more integrative and detailed. Multi-body dynamics model of a light truck s driveline is developed with all the appropriate components, using constrained Lagrangian dynamics. Component flexibility is included for driveshaft pieces, rear axle half-shafts and the suspension elements. The connectivity of the components is accurately modelled such as the floating effect of rear half-shafts, linear bushings between driveline components to chassis connections, as well as the non-linear effect of tapered roller bearings, supporting the wheel hubs and gears. Furthermore, integrated to the previously described large scale model a detailed hypoid gear pair model is devised. This incorporates micro-scale physics for tooth contact analysis to predict geometric properties and deflections for the gear pair. At the same time thermo-elastohydrodynamic lubrication theory with non-Newtonian friction is applied. All these phenomena at different physical scales, such as large displacement rigid body dynamics and analytical equations for the detailed model are solved simultaneously, all within the same modelling environment. This multi-physics, multi-scale approach has not hitherto been reported in the literature, and constitutes a significant contribution to knowledge. Comparative studies of the model predictions and detailed vehicle tests are carried out, the combination of which points to resonant conditions in system responses and flexible component behaviour, coincident with the adverse conditions in the hypoid gear meshing. It is shown that vehicle drive and coast conditions, promoting teeth pair separations lead to irregular (improper) meshing of the differential gears. Such conditions induce impulsive actions that promote the axle whine phenomenon. This is a major finding of the research and contributes to a better understanding of the axle whine problem.
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Venkatesan, Balaji Srinivasan. "Modeling, Simulation and Correlation of Drag losses in a Power Transfer Unit of an All- Wheel Drive System." Thesis, KTH, Skolan för industriell teknik och management (ITM), 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-283800.
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A Power Transfer Unit (PTU) of an All-Wheel Drive System is a hypoid gear transmission unit that distributes the power from the vehicle transmission to all wheels of the vehicle. This thesis aims at increasing the fidelity of the analytical power loss calculation methods through test data correlation and develop a 1D simulation model that can be used to evaluate the drag losses in the PTU at early design stages. Firstly, the analytical methods to predict the frictional losses and oil churning losses due to the hypoid gearset, rolling bearings and seals immersed in oil are studied. Several drag loss tests with different combinations of internal components, bearing preloads and with/without the presence of oil were previously conducted on the PTU at different speeds and temperatures at zero torque. The power losses are computed in ROMAX Energy and Excel using different analytical methods available in the literature for each component in the PTU. Then the results from the drag loss tests are segregated component-wise for data correlation with the losses evaluated previously. Based on the data correlation, modification factors are introduced for all analytical methods to match the segregated test results. The demand in the automotive industry to reduce time to market is high. Hence, system-level simulation was chosen as a solution to assess the system efficiency at early concept design stage, saving a lot of time and aid the detailed design. 1D simulation technique is used to study the total power loss of the PTU to optimize its design. The thesis is aimed at developing a 1D system model of the PTU in a commercial tool called LMS AMESim, to evaluate the total power loss of the unit. Inbuilt component models from the software library are used to build a sketch of a simplified lumped mass model of the physical system. The model is simulated in a time domain temporal analysis. The total power loss results simulated using AMESim are compared to the efficiency tests results conducted at different torque levels and ROMAX results. Comparisons between the simulations and test data shows that the system model is accurate and can be used in predicting the power losses in the PTU in the early design stages. This model can also be used to study the influential factors through sensitivity analysis of different parameters which can be done as an extension to the current scope of this work.<br>En kraftöverföringsenhet (PTU) i ett fyrhjulsdriftsystem är en hypoidväxellådsöverföringsenhet som fördelar kraften från växellådan till alla hjul i fordonet. Det rapporterade arbetet syftar till att öka konfidensen i de analytiska beräkningsmetoderna för effektförlust genom testdatakorrelation och genom att utveckla en 1D-simuleringsmodell som kan användas för att utvärdera dragförlusterna i PTUn i tidiga designfaser. För det första studeras analysmetoderna för att förutsäga friktionsförluster och plaskförluster på grund av hypoidväxeln, rullager och tätningar nedsänkta i olja. Flera ”Drag Loss”-tester med olika kombinationer av interna komponenter, lagerförspänningar och med / utan närvaro av olja utfördes tidigare på PTU vid olika hastigheter och temperaturer utan pålagt moment. Effektförlusterna beräknas i ROMAX Energy med olika analysmetoder tillgängliga i litteraturen för varje komponent i PTU. Sedan separeras resultaten från dragförlusttesterna komponentmässigt för datakorrelation med de tidigare utvärderade förlusterna. Baserat på datakorrelationen införs modifieringsfaktorer för alla analysmetoder för att matcha de segregerade testresultaten. Efterfrågan inom fordonsindustrin att minska tiden till marknaden är hög. Därför väljs simulering på systemnivå som en lösning för att bedöma systemeffektiviteten i ett tidigt konceptdesignfas, vilket sparar mycket tid och underlättar den detaljerade designen. 1D-simuleringsteknik används för att studera PTUns totala effektförlust för att optimera dess design. Arbetet syftar till att utveckla en 1D-systemmodell av PTU i ett kommersiellt verktyg som heter LMS AMESim, för att utvärdera enhetens totala effektförlust. Inbyggda komponentmodeller från programvarubiblioteket används för att skapa en skiss av en förenklad modell av det fysiska systemet. De totala effektförlusterna beräknade med AMESim jämförs med effektivitetstestresultaten vid olika vridmomentnivåer och ROMAX-resultat. Från korrelationen med testresultaten observeras att systemmodellen är korrekt och kan användas för att förutsäga effektförlusterna i PTU i de tidiga designstadierna. Denna modell kan också användas för att studera de viktigaste faktorerna genom känslighetsanalys av olika parametrar, vilket kan göras som en förlängning av detta arbete.
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LIN, ZHI-YANG, and 林志陽. "Characteristic study of hypoid gears." Thesis, 1991. http://ndltd.ncl.edu.tw/handle/38414524691468694372.
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Lin, Chung-Yunn, and 林忠運. "Computer-Aided Manufacturing of Spiral Bevel and Hypoid Gears." Thesis, 1996. http://ndltd.ncl.edu.tw/handle/56247427962566945257.
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CAI, MING-HUANG, and 蔡明晃. "A study on the mathematical model of hypoid gears." Thesis, 1987. http://ndltd.ncl.edu.tw/handle/97168568313875216022.
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Shih, Yi-pei, and 石伊蓓. "STUDY ON THE FLANK MODIFICATION OF FACE HOBBED HYPOID GEARS." Thesis, 2007. http://ndltd.ncl.edu.tw/handle/29161170316435083375.
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博士<br>國立中正大學<br>機械工程所<br>95<br>Based on the theory of gearing and differential geometry, we develop a mathematical model for the universal face-hobbing hypoid gear generator that can (1) simulate both existing face-hobbing and face-milling cutting systems; (2) calculate tooth surface geometry; and (3) analyze contact performance of hypoid gears. Applying the proposed mathematical model to universal flank modification and correction methods for both face milled and face hobbed hypoid gears substantially shortens the time needed for new hypoid gear set development.
Specifically, this dissertation proposes solutions to six research problems:
(a) First, based on the theory of gearing, differential geometry and the universal face-hobbing hypoid gear generator, we derive a mathematical model for face hobbed hypoid gear tooth surfaces. This model contains three modules: a cutter head, an imaginary generating gear, and the relative motion between the imaginary generating gear and the work gear. Given its modular arrangement, the model is suitable for the development of an object-oriented programming (OOP) code. Not only can this mathematical model simulate existing face hobbed hypoid gears with either a single or dual cutter head, but it includes most existing flank modification features and can be easily simplified to simulate the face-milling cutting.
(b) Second, based on the theory of gearing and the universal bevel gear-rolling tester, we derive a mathematical model of no-load tooth contact analysis (TCA) for the face hobbed hypoid gear. This model enables evaluation of the meshing and contact characteristics between the contact surfaces of hypoid gears.
(c) Third, using the proposed mathematical models, we investigate the tooth geometries and TCA results of existing face hobbed hypoid gears with cutting methods such as Klingelnberg’s Cyclo-Palloid, Oerlikon’s Spiroflex and Spirac, and Gleason’s TriAC® formate processes.
(d) Fourth, based on the proposed mathematical model of tooth surfaces and the sensitivity analysis, we develop a general flank correction methodology for both face milled and face hobbed hypoid gears that aims to minimize the flank deviations caused by machine error and heat treatment deflection during gear cutting. According to the measured flank deviations and the flank sensitivity matrix produced for the design parameters, the corrections for the design parameters can be obtained by linear regression. These corrective design parameters are then applied to the gear cutting machine simulation program to calculate the modified tooth surfaces, which are then compared with the theoretical tooth surfaces to assess the correction result.
(e) Fifth, based on the ease-off topography of the gear drive and the sensitivity analysis, we develop a flank modification methodology for face hobbed hypoid gears that can be used to optimize the tooth surface geometries of face milled and face hobbed bevel gears and so improve their contact performance. After using the equation of universal face hobbed hypoid gear tooth surfaces to establish a mathematical model for the ease-off topography of the gear drive, we analyze the sensitivity of the ease-off to each design parameters including cutter parameters, machine settings, and auxiliary flank modification (AFM) motion parameters. According to this sensitivity matrix and the deviations between the optimum and initial ease-off, the modifications of pinion design parameters for obtaining tooth surfaces with an optimum ease-off topography can be determined by linear regression. This proposed flank modification methodology can also be used as the basis for a general technique of flank design for similar gear types.
(f) Sixth, based on the six-axis Cartesian-type CNC hypoid gear generator, we establish a mathematical model for hyoid gears. Specifically, we obtain the six-axis movement for both face milling and face hobbing operations by way of the conversion from a universal cradle-type to a six-axis Cartesian-type machine. Using this six-axis mathematical model, we then develop a kinematic flank correction method that can be used directly to modulate the six-axis movement for producing hypoid gear tooth surfaces without machine-setting conversion. The proposed model can also be used to obtain a free-form flank correction.
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Lai, Wei-Chuang, and 賴威全. "Study on the manufacture and analysis of chamfering for hypoid gears." Thesis, 2019. http://ndltd.ncl.edu.tw/handle/3uuzuw.
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碩士<br>國立中正大學<br>機械工程系研究所<br>108<br>The chamfering and deburring may be underestimate and even out of consideration during the manufacturing process because of the high-cost and time-consuming. However, gears without chamfering and deburring could cause the injury of workers or inefficient of gear meshing. In domestic, there are few gear cutting machines including chamfering device simultaneously. The chamfering and deburring process is usually off-line. This thesis proposes the method for chamfering and deburring gears on-line by setting up the chamfering mechanism on the hypoid gear cutting machine to increase the efficiency of manufacturing.
The study on this thesis focus on the design of the mechanism and the NC path planning for chamfering and deburring process. Firstly, the tooth flanks are established by the existing mathematical model of hypoid gear. Secondly, the NC path planning is programing based on the profile of gear and the geometry of chamfering. In order to design the tooling path for chamfering, we select the appropriate chamfering tool and establish the transformation matrices of gear cutting machine. The absolute positions for chamfering can be derived based on some geometric constraints. The derived mathematical model for chamfering and deburring gears are verified using the CNC machining simulation software VERICUT®.
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Wasif, Muhammad. "A new approach to CNC programming for accurate multi-axis face-milling of hypoid gears." Thesis, 2012. http://spectrum.library.concordia.ca/977263/4/Wasif_PhD_S2013.pdf.
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A pair of hypoid gears refers to a pinion and a gear with skew axes. Hypoid gears are crucial to some power transmission systems, such as those of helicopters, power generation machines and automobiles. However, the design and manufacturing of hypoid gears are quite difficult. Currently, the major parameters of hypoid gears are calculated, but the geometries of the gears are not fully defined. To machine a hypoid gear, parameters of cutting systems are determined according to the gear design, whereas, settings of CNC machine tools with the machining parameters are also computed. The existing hypoid gears machining methods use the simplified blade model of the cutting systems, resulting in large errors in the machined gears. This new work proposes an accurate approach, to determine the parameters of the cutting system blades, for the face-milling of hypoid gears. In this work, a parametric model of the blades is established; and according to the hypoid gear parameters, the pressure angle and the cutting system radius are precisely calculated.
Currently, hypoid gear engineers can use special CAD/CAM software to design the gears and to calculate machine settings. Unfortunately, these software are developed only for particular machine tools; it cannot be used for hypoid gear machine tools of different configurations. Moreover, few technical articles has been published to clearly address challenges in the CNC programming and post-processing for the multi-axis face-milling of hypoid gears, such as the parameters determination of a cutter system, its location and orientation calculation and CNC programs generation. To solve the current problems, another part of this research proposes a generic approach to CNC programming and post-processing for gear face-milling. The main contributions of this part includes (1) a new mathematical model to calculate the cutter system location and orientation and (2) a generic post-processing method to establish the machine kinematics chain and to compute the coordinates of the machine axes in face-milling. This approach provides a general and accurate methodology for the face-milling of hypoid gears on any machine tools and can be directly applied to the hypoid gear manufacturing for better quality.
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Xie, Shuangxi. "An Accurate Approach to Modeling the Genuine Tooth Surfaces of the Face-Milled Spiral Bevel and Hypoid Gears." Thesis, 2012. http://spectrum.library.concordia.ca/36300/1/Xie_PhD_S2012.pdf.
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Shun-Yu-Yang and 楊舜宇. "Study on the Unitool Cutting Method for Hypoid Gear." Thesis, 2014. http://ndltd.ncl.edu.tw/handle/70770608440989729997.
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碩士<br>國立中正大學<br>機械工程學系暨研究所<br>102<br>Based on the theory of gearing and differential geometry, a novel uni-tool manufacturing process for hypoid gear set is developed. In the past, the cutter geometry for pinion cutting is derived according to the local synthesis data at the calculation point on the driving and coast gear tooth surfaces. The point radius difference between the inside blade (I.B.) and outside blade (O.B.) of the pinion cutter might be too big to fit in the same head cutter. Therefore, the driving and driven sides of pinion are usually cut in the different hypoid generator with different head cutter. In order to make sure the I.B. and O.B. of pinion can be installed on the same cutter head, a novel hypoid gear uni-tool design process is developed by modifying the I.B. and O.B. pressure angle to adjust the point radius difference and making the pinion and gear cutter cone surface coincides with each other in the pitch plane. The point radius difference of I.B. and O.B. is controlled within the allowable range to fit in the same cutter head. With this uni-tool feature, both side of tooth surface of pinion can be cut in the same CNC hypoid generator in the same cutting cycle.
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CHEN, SHI WEI, and 陳仕偉. "Study on the conjugate condition for the hypoid gear pair." Thesis, 2016. http://ndltd.ncl.edu.tw/handle/10368496348558610794.
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碩士<br>國立中正大學<br>機械工程系研究所<br>104<br>Based on the theory of gearing and differential, this thesis introduces a new method of hypoid gear manufacturing process. In the past, the point radius difference between the inside blade and outside blade of the pinion cutter may not be fit in the same head cutter. Therefore, both side of pinion tooth have to cut in different CNC hypoid generator with different head cutter. By using pinion curvature and cutter pressure angle adjustment, the point radius of the inside blade and outside blade can be fit in the same cutter head.
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Chen, Szu-Hung, and 陳思宏. "Study on the Cutting Time of the Hypoid Gear Tooth Flank." Thesis, 2014. http://ndltd.ncl.edu.tw/handle/5kj8hj.
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博士<br>國立中正大學<br>機械工程學系暨研究所<br>103<br>According to the relationship of transformation matrices among the universal face-milling methods by Klinglnberg and Gleason, this study proposes a cutting simulation method for face-milling that involves using SolidWorks application programming interface (API) functions. The proposed cutting simulation method can be used to simulate the face-milling cutting method by Gleason. The machine and cutting settings were verified by performing simulations, and the feed-rate was adjusted to obtain a constant cutting torque throughout the process to decrease the cycle time based on the simulation results. For mass production, the gear fixture can be manufactured according to the simulated 3D model to prevent the cutter from striking the fixture throughout the process. The proposed cutting simulation method can reduce the time involved in designing and manufacturing new hypoid gears. Consequently, the cost of product development can be reduced and the efficiency can be increased simultaneously. The cutting simulation method can also be used to analyze the Gleason cutting settings before cutting is performed.
This dissertation proposes solutions for three research problems.
(a) A mathematical model of a universal face-milling hypoid-gear generator was created to perform the cutting simulations. Mathematical models of Gleason and Klinglnberg hypoid-gear generators were developed to convert the machine settings to a universal face-milling coordinate system to analyze the machine and cutting settings. The mathematical models of six-axis and five-axis computer numerical control (CNC) machines were developed for manufacturing a gear set based on existing CNC machines. The relationships among the machine settings can be determined by comparing the components of the transformed matrix in the universal face-milling coordinate system with those by Klinglnberg and Gleason, as well the six- and five-axis CNC machines. The relative position between the head cutter and workpiece in the universal face-milling coordinate system can be determined according to the corresponding machine settings by Klinglnberg and Gleason. A cutting simulation was performed to verify the machine settings and determine the cutting settings derived from the simulation results. Finally, the G-codes were obtained to manufacture a gear set on the six-axis or five-axis CNC machines.
(b) Using SolidWorks API functions, we developed computer software to simulate a hypoid-gear cutting generator based on a universal cradle-type hypoid generator. The software can simulate existing cutting methods. The relative position between the head cutter and workpiece was verified using the software to prevent the cutter, workpiece, and machine unit from colliding throughout the process. After the cutting simulation, the overlap volumes and corresponding generation positions are recorded and fitted as polynomial curves for planning the feed-rates throughout the cutting process. The geometry of a fixture that would not be struck by the cutter can thus be determined. A fixture with high rigidity can be manufactured according to the simulated 3D model. The machine settings, cutting settings, G-codes, and fixture can be verified using the developed software to reduce the costs and risks involved in manufacturing the gear by using general six-axis and five-axis machines. A solid model of finished hypoid gear can be used to verify the machine settings and for further finite element method analysis.
(c) The material-removal polynomial curve can be applied to analyze and adjust the cutting settings of the Gleason model to reduce the machining time at an identical maximal cutting torque. A hypoid-gear cutting plan was developed to implement the constant material removal rate (CMRR) concept by varying the feed rate and cradle roll velocity (CRV) to retain the cutting torque within a certain range throughout the cutting process, thereby reducing the impact force at the cutter-engage point. The proposed CMRR process was experimentally verified using a six-axis CNC hypoid-gear generator by measuring the electrical current of the cutter spindle motor, which is proportional to the cutting torque.
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CIOU, JHE-CI, and 邱哲淇. "Study on the Tool Sharpening Method for the Hypoid Gear Head Cutter." Thesis, 2016. http://ndltd.ncl.edu.tw/handle/14055826733391131186.
Full textAbstract:
碩士<br>國立中正大學<br>機械工程系研究所<br>104<br>Based on the Gleason’s RSR type cutting tool of hypoid gear, the mathematical model of hob sharpening machine, including the coordinate systems and the clamping device for grinding the cutting blade is presented in this thesis. Using the VERICUT software to simulate the grinding process and compare the result with the mathematical model.
There are two methods to verify the correct of the the mathematical model of hob sharpening machine for grinding the cutting blade in this thesis. One is the simulation, and another is experiment. Using the VERICUT software to build the hob sharpening machine through importing the STL file of SolidWorks 3-D models, and to simulate the grinding process via the NC program. The 3-D model of cutting blade came from the result of simulation can be measured in the SolidWorks to check the relative angles with the designed values. In the end, using the actual hob sharpening machine to grind the cutting blade, and measuring it on the Gleason No.562 blade inspectipn device machine.
According to the mathematical model , the computer simulation, and the actual experiment of blade grinding process, the probability of substituting the hob sharpening machine for the blade grinding machine is confirmed.
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Wu, Chun-Lin, and 吳俊霖. "Tool Path Planning and Computer Simulation for Hypoid Gear Manufacturing using 6-Axis CNC." Thesis, 2006. http://ndltd.ncl.edu.tw/handle/26075708068137220832.
Full textAbstract:
碩士<br>國立中正大學<br>機械工程所<br>95<br>Gear has been widely used for more than two centies. It is very important in industry since it is still used nowadays. But there are many limitetions in gear manufacturing. Most manufactures of gears use a special cutting tool and a dedicated machine, which produce good quality gear and efficiently. However the gear machining are very expensive and some certain companies dominate the technology of gearing and global market share. Domestic gear vendors still use the old type machine to produce gears. So it is important to develop advanced gearing technology.
This research developed the rough cut for gear machining based on an input of finish cut g-codes. It analyses the depth of cut and cutting force. The results and simulated by VERICUT program. The main contribution for this research is the analyses on cutting areas and cutting force that avoid the tool wears rapidly due to large depth of cut. The resulted cutting speed and rotation speed is taking into account of tool life.
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Wei, Chiang Ta, and 江大偉. "Study on the Generalized Conjugate Conditions among the Hypoid Gear Set and the Correspoiding Generators." Thesis, 2000. http://ndltd.ncl.edu.tw/handle/11284976716576021292.
Full textAbstract:
碩士<br>國立中正大學<br>機械系<br>88<br>Most mathematical models proposed in the literatures are usually bonded to specified gear cutting process with certain kind of hypoid generator. A mathematical model of universal hypoid generator is deduced by theory of gearing. At the same time, the proposed mathematical model simulates the face-milling, face-hobbing, plunge-cutting, and bevel-worm-shaped hobbing processes with either generating or non-generating cutting for hypoid gear. Application of the proposed mathematical model: the majority of the existing cutting method can be simulated by the proposed mathematical model with machine setting conversion. Based on the relative motion of two bodies, knowing that the relative motion of two gears may be represented as a screw motion. And, the location and direction of the screw axis of relative motion as well as the screw parameter of relative motion can be determined. Consider the conjugate surfaces of meshing, screw parameters of relative motion must be coincided. Besides, instantaneous axes of tooth surfaces have to pass through one point or coincide in the same coordinate system. Therefore, it just fulfills the conjugate conditions of contact tooth surface.
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Hsieh, Tung-Han, and 謝東翰. "Mathematical Model of The Six-Axis CNC Machine for Grinding Cutting Tools of Hypoid Gear." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/76722477212121657892.
Full textAbstract:
碩士<br>國立中正大學<br>機械工程學系暨研究所<br>103<br>This paper aims at building a mathematical model of the six-axis CNC machine for grinding cutting tools of hypoid gear, is based on the Oerlikon’s grinding machine, and input STL file to build the model of machine on VERICUT 7.3, and verify the mathematical model of cutting edge which derived by Lee, Yi-Hui, the student from Department of Mechanical Engineering of National Chung Cheng University.
Using Mathematica 9.0 output point data of cutting edge to check the positions; input the designed parameters to calculated the displacement and angle, and simulate cutting processes, and measure the model, imported into Solidwork3D.
To Verify correctness of mathematical model of the six-axis CNC machine for grinding cutting tools of hypoid gear by verifying designed and derived cutting edge.
Keywords:Cutting Tools, Grinding Machine, Six-Axis
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Sie, Zong-Ru, and 謝宗儒. "A Study of Multi-Action Warm Forging Die Set for the Hypoid Gear of Car." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/18642707036062894673.
Full textAbstract:
碩士<br>國立高雄第一科技大學<br>機械與自動化工程研究所<br>103<br>Hypoid Gear differential mechanism of automobile , it can increase the cornering balance of the car, With the growth of the automobile market, Sharply increase in requirement, machining by gear cutting machine is the process. But it takes a lot of time to machining, high machining costs, poorer strength ,poorer utilization of material, While using forging can increase the flexural strength and impact strength, Save time and material , Therefore this research using Vertical multi-action forging die set to develop and study, The material is using 8620 Low-carbon nickel-chromium-molybdenum steel.
First of all using the Computer-assisted analysis software to simulate the one-way and two-way vertical multi-action’s actuation, compare the formability , Molding load, Die stress , Choice the best forming formula , and match up 800℃、900℃、1000℃these three temperatures to simulate ,And using these data the Forging Experiment.
Simulation results show that two-way multi-action forming vertical load and die stress are superior mold-way vertical multi-action, and the mold life better. Bidirectional vertical multi-action at three temperatures were able to shape, when the temperature rises 100℃, forming a load drop of about 20%.
Discovering by the forging experiment results, When the billet’s temperature is 800℃ the tooth profile of gear is not fully formed yet. Billet’s temperature around 900℃ to 1000℃ can be fully formed. Tooth profile appearance has significantly oxide while billet’s temperature around 1000℃. The flow line of the forging workpiece of the multi-action forging die set is well-distributed and complete . Compare with the Topography of the forging gear and the machining gear. The results shows the area of the tooth has the maximum deviation. The maximum unilateral deviation is 0.3mm, Because the straight edges need to change to corner edges of the forging gear. Increase the strength of the mold , The other tooth surface of the deviation is less than 0.1mm, the multi-action forging die set process can save the material 24% compare to former process.
Finally the forging experiment has the same trend of the simulation experiment, Therefore in the future the forming of Hypoid Gear can sharply reduce manufacturing time and increasing material utilization by vertical multi-action forging process.
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Huang, Chang-Sheng, and 黃昶勝. "A study on the directly measuring system of the modern six-axis CNC hypoid gear generator and mathematic model of the flank correction." Thesis, 2009. http://ndltd.ncl.edu.tw/handle/61523852988126374780.
Full textAbstract:
碩士<br>國立中正大學<br>機械工程所<br>97<br>The modern six-axis CNC hypoid gear generator has enough degree of freedom to apply existing cutting systems for spiral bevel and hypoid gears. Numerical control has made it possible to perform nonlinear flank modification features. This paper research project and aims to develop the automatic flank correction system for hypoid gears. Gear cutting, flank measurement and flank correction processes can be achieved in the same machine. Based on the proposed universal hypoid gear generator, the flank correction method will be developed. Then we shall focus on the establishment of online measurement system for flank topography. The mathematical model of flank measurement will be studied. Based on the model, we can plan the NC codes of flank measurement. And the flank deviation can be obtained by comparing the measurement data with theoretical nominal data. We can correct every machine geometry error with the sensitive matrix of the machine geometry error. Last it will be developed that the flank correction method based on the six-axis hypoid gear generator. Therefore, the machine setting correction can be applied directly without conversion from the universal machine to six-axis hypoid gear generator. We can develop the cutting software of the online measurement system and flank correction .The developed technologies in the research also can be applied in other type machine tools.
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Schaefer, Steffen. "Verformungen und Spannungen von Kegelradverzahnungen effizient berechnet." Doctoral thesis, 2017. https://tud.qucosa.de/id/qucosa%3A30994.
Full textAbstract:
Diese Arbeit beschäftigt sich mit speziellen Methoden zur näherungsweisen Berechnung der Zahnverformungen sowie -spannungen im Kontext der Zahnkontaktsimulation von Kegelrad- und Hypoidverzahnungen. Die näherungsweise Berechnung ermöglicht kurze Simulationszeiten und ist damit die Voraussetzung für eine effiziente Verzahnungsoptimierung. Die Anwendung neuer Fertigungsverfahren ermöglicht es, dabei geometrische Ausprägungen des Zahnprofils, Zahnfußes und der Flankentopologie zu realisieren, die mit den speziellen Methoden der näherungsweisen Berechnung bisher nicht oder nur unzureichend genau abgebildet werden können. In der vorliegenden Arbeit werden deshalb Näherungsmethoden entwickelt, mit denen z.B. auch Zahnprofile mit großer Asymmetrie, elliptischen Zahnfußkurven und logarithmischen Flankentopologiemodifikationen zuverlässig berechnet werden können.:1 Einleitung
2 Stand der Technik
2.1 Zahnkontaktsimulation
2.2 Die Verzahnungsgeometrie als Basis der Zahnkontaktsimulation
2.3 Methoden für die Zahnkontaktsimulation
2.3.1 Komplexe Methoden für die Verformungs- und Spannungsberechnung
2.3.2 Näherungsmethoden für die Verformungs- und Spannungsberechnung
2.4 Verzahnungen mit Sondermerkmalen
3 Zahnkontaktsimulation auf Basis der Einflusszahlenmethode
3.1 Herangehensweise bei der Betrachtung
3.2 Zerlegung der Verformungen und Spannungen in lineare und nicht lineare Anteile
3.3 Annahmen für die Formulierung des Zahnkontaktproblems
3.4 Bestimmung der potenziellen Zahnkontakte
3.5 Einflusszahlenmethode
3.6 Lösung des reibungsfreien Zahnkontaktproblems
3.7 Radkörpereinfluss
3.8 Wechselwirkung zwischen den Zähnen
4 Näherungsweise Biegeverformungsberechnung
4.1 Vereinfachung der Verzahnungsgeometrie
4.2 Berechnungsmethode
4.3 Allgemeine Verformungsabklingfunktion
4.3.1 Allgemeine Verformungsabklingfunktion für den unendlich langen Zahn
4.3.2 Allgemeine Abklingfunktion für den endlich langen Zahn
4.3.3 Berechnung der Zahnverformung unter Einzelast mittels FEM
4.3.4 Einfluss der Kraftangriffshöhe und der Profilform
4.3.5 Fehlerverhalten der allgemeinen Verformungsabklingfunktion
4.3.6 Einfluss der veränderlichen Normalschnittgeometrie
4.4 Bezugswert der Biegeverformung
4.4.1 Näherungslösung
4.4.2 Wahl einer Methode zur Verbesserung der Bezugswertberechnung
4.4.3 Auswahl des BEM-Verfahrens
4.4.4 Verfahrensbeschreibung für das BEM-Programm-Modul
4.4.5 Auswertung der BEM-Verformungen an der Stelle einer Streckenlast
4.4.6 Überprüfung des BEM-Programm-Moduls und Genauigkeitsbewertung
4.4.7 Effiziente Berechnung des BEM-Bezugswerts
4.5 Korrekturen für den Ersatzzahn
4.5.1 Stirnseitenunstetigkeit
4.5.2 Krümmungseigenschaften des Zahnes
4.6 Zahnberandungseinfluss
4.7 Berechnung der verbesserten Biegeverformungseinflusszahlen
5 Näherungsweise Berechnung der Kontaktverformung und -spannung
5.1 Vereinfachung der Kontaktgeometrie
5.2 Berechnung der Kontaktverformungseinflusszahl und der Kontaktspannung mit der ZZM
5.3 Komplexe Einflüsse auf die Kontaktverformung und -spannung
5.3.1 Wechselwirkungseinfluss
5.3.2 Zahnberandungseinflüsse
5.4 Erweiterung der ZZM zur Berücksichtigung von Kopfkanten
5.5 Verbesserte Berechnung der Kontaktverformungseinflusszahl und der Pressung
6 Näherungsweise Berechnung der Zahnfußspannung
6.1 Berechnungsmethode
6.2 Allgemeine Spannungsabklingfunktion
6.2.1 Allgemeine Spannungsabklingfunktion für den unendlich und endlich langen Zahn
6.2.2 Einfluss der Kraftangriffshöhe und der Profilform
6.2.3 Fehlerverhalten der allgemeinen Spannungsabklingfunktion
6.3 Bezugswert der Zahnfußspannung
6.4 Korrektur für den Ersatzzahn
6.4.1 Einfluss des Schrägungswinkels auf die Zahnbreitenlage des Zahnfußspannungsmaximums
6.4.2 Stirnseitenunstetigkeit
6.4.3 Einfluss der Zahnwindung auf die Zahnfußspannung
6.4.4 Einfluss der Flankenlinienkrümmung auf die Zahnfußspannung
6.5 Berechnung der Zahnfußspannung nach der verbesserten Methode
7 Verifikation und Validierung der verbesserten Berechnungsmethoden
7.1 Herangehensweise bei der Verifikation und Validierung
7.2 Verifikation
7.2.1 Allgemeine Vorbetrachtungen zur Genauigkeit
7.2.2 Sensibilitätsstudie
7.3 Validierung
7.3.1 Vorgehensweise bei der Validierung
7.3.2 Ausgewählte Messungen von Paul
7.3.3 Tragbildvergleich an Praxisverzahnungen
7.4 Konvergenzverhalten bei der Zahnkontaktsimulation mit BECAL-BEM
8 Zusammenfassung und Ausblick