Fourth-Order Kinematic Synthesis for Face-Milling Spiral Bevel Gears With Modified Radial Motion (MRM) Correction

The use of a fourth-order motion curve is proposed by Stadtfeld and Gaiser to reduce the running noise of a bevel gear set recently. However, the methodology of synthesizing the tooth surfaces was not clearly shown in the literature. In this work, we proposed a methodology to synthesize the mating tooth surfaces of a face-milling spiral bevel gear set transmitting rotations with a predetermined fourth-order motion curve and contact path. A modified radial motion (MRM) correction in the machine plane of a computer numerical control (CNC) hypoid generator is introduced to modify the pinion tooth surface. With MRM correction, an arbitrary predetermined contact path on the pinion tooth surface with predetermined fourth-order motion curve can be achieved. Parameters of MRM correction are calculated according to the predetermined contact path and motion curve. As shown by the numerical examples, the contact path and the motion curve were obtained as expected by applying the MRM correction. The results of this work can be applied to the pinion, which is generated side-by-side (for example, fixed setting method, formate method, and Helixform method) and can be used as a basis for further study on the motion curve optimizations.