9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea

Methods of and Outlook for the Modeling of Spiral Bevel Gears

Ding Han1, AdayiXieeryazidan 1,* ,Wang Zhigang1
1

School of Mechanical Engineering, Xinjiang University, Urumqi, China

Abstract: Accurate modeling of spiral bevel gears laid foundation of the vital technology namely Tooth Contact Analysis (TCA) and correction of the deviation of tooth surface in their digitized manufacturing. It summarized the related achievements and divided modeling approaches of the spiral bevel gears into three categories, which are modeling by discrete points on the tooth surface and suturing curves and simulation machining, and generalized their vital ideas and steps in modeling of the spiral bevel gears. What is more, according to the analysis of some problems and inadequacies, and some advanced ways and ideas about the modeling, three development direction were proposed for modeling technology of spiral bevel gears in the future, that are high accuracy and high efficiency and high flexibility, so as to provide some methods for faster and more accurately design of spiral bevel gear and machining. Key words: Accurate modeling, Spiral bevel gears, Digitized manufacturing, Tooth Contact Analysis (TCA), Simulation machining. 1. Introduction
Spiral bevel gear drives are extensively used in the crossing or intersecting axis power transmission. Due to the high contact ratio, they are provided with some performances such as the higher carrying capacity, the smooth transmission, the lower noise and so on [1-2]. Therefore, their design and manufacturing are still hot topics of research that play a vital role in automobile, helicopter, machine tool, and in other branches of industry [3-5]. Their structure of the tooth surface are quite complex, and manufacturing precision and quality play direct impact on transmission efficiency of power machinery, noise, movement precision, service life performance and so on [6]. The full-featured Phoenix II CNC milling machine with five-axis linkage independently researched and developed by American Gleason Corporation, at the same time, which is equipped with the most state-of-the-art Gleason Expert Manufacturing System (GEMS) for spiral bevel gears, represents the highest level of digital manufacturing all over the world[7]. The tooth contact analysis (TCA) and correction of the deviation of tooth surface technologies based on the model of gear drives had been the core of the GEMS [8]. Recently, researches on the spiral bevel gears in design filed at home and abroad have become increasingly deep, and been working to digitized and diversified development and improvement. Accurate modeling can be completed with the various methods and processing which are suitable for special or general purpose machine tools to complete a variety of different or exceed the specifications of the gear. In this paper, the research achievements of modeling at home and abroad are analyzed and summed up from three aspects: a) The point-to-surface modeling by discrete points, the key step is to solve the or obtain the discrete points on the tooth face [8-11]; b) The line-to-surface modeling by suturing curves, its core is the solution of tooth profile curve equation expression [12-15]; c) Modeling by the simulation machining based on virtual reality technology, the vital idea is equivalent conversion and program control in the controlling the movement of cutter and gear blank [16-20]. In addition, based on the related domestic and foreign research are analyzed and summarized, and the existing problems and some related means and methods to solve problems in the modeling research, development directions with modeling of the tooth surface was prospected, in order to create condition of accurately and efficiently design, analysis and machining for the spiral bevel gears: a) The precision of tooth surface will be higher and higher; b) The efficiency of the of the modeling will be higher and higher; c) Modeling method will be more and more flexible.

2. Basic ideas of modeling of spiral bevel gear

2.1 Meshing theory about spiral bevel gears In the recent main study on the modeling, neither modeling by equations of tooth surface nor by cutting processing are based on the meshing theory about spiral bevel gear. It is also named principle of conjugated curved surfaces [21], and in the main consideration with contact transmission between two

Corresponding author: AdayiXieeryazidan; E-mail: adayxj@126.com; Tel: +15009002703

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea motional curved surfaces. As shown in Fig. 1(a), they are a pair of gear drives in engagement; in Fig. 1(b), it presents the meshing theory about spiral bevel gears. Two motional curved surfaces 1 and 2 are contact transmission and in tangency at the point M, their common tangent plane is T. Additionally the point O 1 and O 2 are their respective origin of the coordinate system fixedly connected. The vector of the point M on the surfaces 1 is described with r 1 , and its unit normal vector is n 1. Likewise, the vector of the point M on the surfaces 2 is described with r 2 , and unit normal vector is n 2. The m becomes the vector from the point O 1 to the point O 2. Then conjugate curved surfaces should be satisfied with the equations as follows:

= r1 + m r2 n1 = n 2

Above equations can be transformed by the relative differential method, as following equation:

v12 0 n=

where v 12 is relative speed between the two surfaces 1 and 2 . Formula (1) represents basic equations, and formula (2) represents meshing equation.

T
n
M

r
1 2

1 2

O1

O2
1

(a)

(b) Fig.1 The meshing theory about spiral bevel gears.

2.2 Basic idea of modeling Modeling of spiral bevel gear is described into a general process of gaining the gear solid model with meshing theory and machining approaches by means of correlation analysis and drawing software. Its basic idea is demonstrated in the Fig. 2: Taking advantage of the 3D mapping and data analysis software, it can complete general modeling process from point to surface, from the point to the line and then surface, from line to surface, or direct cutting simulation. During the modeling, many critical steps, such as extraction of tooth surface data points, the point-to-line fitting, structuring from line to surface, and application of simulation machining and other means, are given bold attempts and innovations by researchers, finally all kinds of effective modeling methods are obtained.
Discrete points on the tooth surface Equations of tooth surface Tooth profile curve Model of gear Simulation for the actual machining

Fig.2 Basic idea of modeling

3. Methods of modeling of spiral bevel gear

In the early days, Professor Faydor L. Litvin [1-4] has laid the theocratic foundation of modeling through the derivations of equations of tooth surface where the gear is enveloped and generated by tool paths, in the light of tooth meshing theory and design of tool shapes and motion conversion about corresponding cutting process. Furthermore, Korean well-known scholar S. H. Suh has got rid of the 2

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea traditional principle and methods, and made creative application of the spherical involutes curve theory in modeling of spiral bevel gears, which put up with a new pathway of parametric modeling [5]. In China, in view of the spiral bevel gear derives play an irreplaceable position in the field of industry, government had been increasing investment and research. There are so many research institutes such as State Key Laboratory of the Gear Transmission in Chongqing University, Central South University, Northwestern Polytechnic University, Zhengzhou Institute of Gear and so on [8] have carried out related studies, and expanded and improved the area for research of spiral bevel gears continuously. In this paper, the modeling of spiral bevel gears are divided into three aspects reviewed by combining with research literature about the spiral bevel gears in recent years at home and abroad. 3.1 The point-to-surface modeling by discrete points It is the early and traditional method that is on the base of generated equation of gear tooth surface taken the derivation by Professor Litvin. Firstly, the software (such as Matlab) is applied to solve the equations of tooth surface, and which obtains information about discrete points evenly distribute on the gear tooth surface (as shown in the Fig.3). Then, it is necessary to take drawing operations after importing the data of these discrete points into all kinds of relevant 3D modeling software (pro/E, CATIA, SolidWorks, etc). Finally, the model will be received by constructing surfaces with above points directly, or building the boundary curves of tooth with these points and then suturing the curves.
zi xi yi
M

Fig.3 Obtaining the data of discrete points on the tooth surface. The key part of this approach is the processing and acquisition of data information about discrete points on the tooth face by some following ways. (1) By the analysis software: coordinate information about data points on tooth surface are solved through the software with data analysis and processing functions, such as Matlab or TMSL function library under the DENQNF subroutine[8,22-23]. (2) By measuring: some equipment, such as Three Coordinates Measuring Instrument (Fig.4 (a)) has tooth surfaces of machining parts in direct measurement and data collection [9,24]. (3) By simulation machining: firstly, simulation should be completed according to the practical machining, then calculate parameters data on points by programming [10]. (4) By intersecting faces: as shown in Fig.4, the surface cone, back cone, root cone and former cone are all intersected with the tooth surface, and then they form four intersecting lines. The data comes out by collecting points on the four boundary lines of tooth surface [11].
Surface cone Tooth surface Back cone

Former cone

Root cone

(a)

(b) Fig.4 Collect the points by the measuring (a) and the intersecting surfaces (b).

3.2 The line-to-surface modeling by suturing curves At first, mathematical equations of the curve profile are calculated according to the relevant theory. 3

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea Then, equations are imported into the 3D software, which may draw out the basic shape of the tooth surface by the operations. At last, it can export the accurate model after the reconstruction of tooth surface by the use of optimization method such as NURBS to improve accuracy. Among the procedure, the core is the solving [12-14] of the equation expression on the tooth curve and obtainment about the gear tooth profile curves on the base of the general derivation of the equations of tooth surface (Fig.5).
Design of the geometry of the blades Equations of cutting surface of the blades Application of meshing and kinematics theory Equations of the tooth surface

Fig.5 General derivation of equations of the tooth surface. Generally speaking, there have two main solutions because of different theoretical sources. One is base of the meshing theory and related knowledge, to derivate the expression and to figure out the basic tooth profile curves which are exported in the some software such as Matlab, CAXA and so on, and the other is the derivation with the application of the spherical involute curve. By comparison, the former becomes complex and cumbersome, the latter becomes fast and simple, what is more important, easily parameterized. In the solution, the involute curve used for the spiral bevel gear is defined on the sphere, namely the spherical involute curve, which can be solve simply and accurately the derivations of all the equations of tooth surface[5,15,25].

R K K Kt N 0

K0

01

Fig.6 The formation of the spherical involute tooth surface. It is the principle that how to gain the equations of the tooth surface in the use of theory of the spherical involute curve is represented in Fig.6. At the same time, it reveals the formation process of spherical involute tooth surface. When a circular plane is tangent to and doing pure rolling on the base cone OK 0 N, the track of generated curve K 0 K t in the space is formed into a side of the gear tooth surface. The endpoints K 0 and K t on the generated curves form into the tooth profile curves of gear heel and toe. To do so, make both the radius R of circular plane and the rotation angle of the base cone change, with spherical involute basic equation, basic mathematical equation expressions of each part of the tooth curves can be derived, and finally the parametric equations are completed. 3.3 Modeling by the simulation machining based on virtual reality technology It has great practical significance for getting the model through virtual manufacturing technology. In the simulation of the real machine and the processing method, some researchers [16-17] choose the traditional mechanical machine tools (NO.116) and the Format and the Generated for the gear, the Tilt and the Modified Roll for the pinion. Another [18-20] choose the Phoenix II CNC bevel cutting machine, the NC machining method with six axes five linkages [26] is transformed to the traditional, by the equivalent conversion. In the studies, the latter is primary. The study all refers the actual machining [18] as the Fig.7(a), Where there are two important steps , one is the equivalent conversion between the traditional and the Phoenix II CNC bevel cutting machine, anther one is adjustment of the position and orientation of the cutter and gear blank. (i) Equivalent conversion: in order to achieve equivalent processing between the CNC machine tool and the traditional one, the following two equations must be satisfied.
G) C) L(pt ( , , ) = L(pt ( , , )

(3)

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea

C C (O p Pt )(pG ) = (O p P t )(pC )

(4)

where (O p P t ) p is the vector from the cutting tools to the tooth blank; L pt is transformation matrix from the cutting tools to the gear blank; CNC bevel cutting machine is represented by the C; the mechanical machine tool is represented by the G; P and t are the coordinate systems fixed with the gear blank and the cutting tool respectively; (,,)and (, , )is the rotation angles of the three main axes. The solution of above two simultaneous equations are expressed motion parameters of mechanical machine tool represented the CNC cutting machine, so the equivalent conversion can be achieved.
Gear blank

Cutter head

Cutter head

Gear blank

Cutter head

Milling tool

Gear blank

(a)

(b)

(c)

Fig.7 (a) Actual machining; (b) Simulation cutting machining; (c) Simulation milling machining. (ii) Adjustment of the position and orientation: as shown in Fig.7 (b), it mainly includes the relative position at any time is consistent with the actual processing, especially the adjustment at the initial point is particularly important. It is main solution that is the motion parameters from above equivalent conversion can be controlled by the programming. For a sentence, in the software (CATIA, UG, SolidWorks, etc), control program at any moment [19] is carried on by the secondary development. Additionally, in some simulation machining software (VERICUT etc), they can be solved directly by NC program [20].
START
SATAR

Import parametres Start the simulation software Adjust parametres Create new parts Create gear blank

Obtain information about tooth surface Setting the related configurations Creating the workpiece blank Setting processing parameters Compiling machining craft procedure

Create cutter head Adjust position of the cutter Boolean cutting operations
NO

Rotat e gear blank

Generatin g the tool path

Simulation

Cut out a teeth

YES NO

calculation of Tool path

Cut gear tooth surface

YES

Generation of cutter location files

Reconstruction of tooth surface Export gear model

The post-processing
Generating NC code
STOP

(a)

STOP

(b)

Fig.8 The process of simulation machining with special machine tool (a) and general machine tool (b).

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea The general simulation machining process with special machine tool is represented in Fig.8 (a). After entering into simulation processing environment, it should make parametric design of gear blank and the cutter namely imports some parameters used for programming quickly with creating them. And then the accurate position and orientation between the cutter and gear blank must be in the accurate adjustment, so that they can do Boolean cutting operations [27] for a gear tooth surface. At last, the accurate model of spiral bevel gear is exported after reconstruction of tooth surfaces to improve the accuracy. What is more, on the choice of the actual machining way, there are some researchers adopt simulation with general machine tool (Fig.8 (b)) by taking advantages of universal milling [6, 28]. It is so different from the special machine tool processing that provides pathway for the machining, especially big modulus gear are more than technical specifications(Gleason gear system maximum machining diameter for 2590mm). Therefore, the simulation basing the universal milling machining also gradually becomes a kind of gear modeling method. The simulation process (Fig.7(c)) is of a wide variety because of the choice of the simulation software platform. However, it includes some parts basically as follows: (1) Setting the related configurations. They mainly cover the choices of the simulation software platform (such as Pro/E, UG, CATIA, etc), machine tool, the fixture, the cutter, and NC simulation system. Generally speaking, to choose five axes linkage machine tool, and the cutter and the fixture according the manufacturing procedure, and the NC simulation system should be considered it meet the processing object, are advisable. (2) Creating the workpiece blank. It is consist with the material, size in the need, or got by drawing operations. (3) Setting processing parameters. There are the parameters about the cutting tool, cutting feed speed, the feed, spindle rotating speed, the amount of backing, should be set on the base of specific circumstances of actual processing. (4) The pre-processing. It contains compiling machining craft procedure, generating tool path, the simulation and the calculation of tool path in the CAM software. (5) The post-processing. It means transform the tool path into the movement track, and completes NC machining by generating NC code. In this approach, vital step is the compiling machining craft procedure. Firstly, it is turning processing for the forging gear blank , then the milling tooth slots and surfaces, and then grinding the gear tooth surfaces, in order to improve the quality of gear tooth surface processing, finally inspection and adjustment with the grinding gear contact area to complete it. The main processing technology is the milling parts that can be divided into three processes: rough machining of tooth slots, vice-finishing, and then finishing of tooth surfaces.

4. Outlook for the modeling of spiral bevel gear

At present, the vital technology namely Tooth Contact Analysis (TCA) and correction of the deviation of tooth surface in its digitized manufacturing, have been mastered by the Gleason Corporation and never announced [7]. And two technologies are based on the model of spiral bevel gear. Thence, this paper provides three development directions for the future modeling techniques of the spiral bevel gear, combining with the improvement of its manufacturing level and the current status quo. 4.1 The precision of the modeling The foreign cutting precision by taking advantage of high-speed dry can reach the level of 4 or 5. However, our nation is far apart with them. Always there are some problems in the early spiral bevel gear modeling process: (1) Interpolation accuracy in the collecting of discrete points; (2) The derivation and processing of the transitional surfaces; (3) Optimization and reconstruction of the tooth surface after simulation processing; (4) Measurement and correction of deviation of tooth surface. Especially, the transitional surface is a serious problem, and often paid little attention or not mentioned as a result of the complex modeling. However, it is the integral part of the actual machining tooth surface. As shown in Fig.9, a complete tooth profile consists of at least four segments: the segment ab is tooth top; the segment bc is working tooth profile; the segment de is Tooth root; and the connection segment between working tooth profile and tooth root is transition curve cd. Transitional surface is posed by the transition curves, and enveloped with tooth top of the cutting tools or the rounded package of tooth top according to the tool shape [30-32]. Subsequently, more and more researchers pay much attention and begin to solve these problems. They gradually increase the accuracy of modeling in the use of so many optimized approaches, such as 6

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea software data analysis [6,8], derivation of the equation of the transition curve[29-31], reconstruction of tooth surfaces with utilizing functions of curves and surfaces in the NURBS or Bezier [10,32]. For example, the deviation can be calculated in the reconstruction of tooth surfaces by the NURBS after suturing curves, and controlled within 10-8~10-14mm at the main curvature of gear tooth surface [10]. It has been reached a high enough accuracy, but accuracy problems of spiral bevel gear tooth surface still need to be improved.

Tooth top

b c

profile

Working tooth

curve

Transition

Tooth root

Fig.9 The basic components of the tooth profile curve. 4.2 The efficiency of the Modeling Within a variety of modeling methods researchers have proposed, resulting in poor efficiency and practicality are many factors: (1) Theory is too hard to grasp. Merely derivation of the tooth surface equations need familiarity with a lot of meshing principle and the knowledge of the coordinate transformation and gear cutting machining[1-4]. (2) Large amount of data processing. In the acquisition process of the discrete points, it has to use some optimized algorithm for solving nonlinear equations and analysis of related data using the preparation of complex procedures [10, 29]. (3) Cumbersome process and repeated operation. Firstly, a complicated calculation is in need. Then, 3D software trivial operation should proceed. Finally, continue to verify the actual data and do the correction and processing in order to the accuracy requirements [6, 33]. Needless to say, How to get a fast and accurate modeling will become an important topic. The digitized design based on machining simulation technology with the multi-axis linkages CNC machine tool [3435], will become more important research direction. The spherical involute-based fast parametric modeling [15, 25] will also become a new hot spot. Independent development of system software [6, 34] will replace a large number of complicated calculations and operations become the main trend of the research. As the yardstick of the actual processing of the high-quality gear, timeliness and rapid modeling approach will continue to promote the spiral bevel gear manufacturing standards. 4.3 The flexibility of the Modeling In the past, modeling by discrete points, due to the complexity of calculation and derivation of longitud inal process, cause data stability and unrepeatable. And that there have been some problems about integ rity and consistency of modeling platform has based on the lack or limitation of software function. Mod eling problem about big modulus gear that is more than normal tooth system specifications has not bee n considered. Along with the deepening of the research, the modeling method and field are continuousl y widened and perfect. At the same time, with development the cloud manufacturing technology, colla borative design for spiral bevel gear based on the advantages and characteristics of the network resourc es will become a new bright spot. A variety of information resources in design field will be constituted advanced system architecture to achieve seamless data sharing between computer network and user dat abase, and complete flexible collaborative design and manufacturing [37]. Breakthrough of the oneness and limitation of repeated use will are obtained, more and more modeling technology will become digital, and gradually forms a flexible and multivariate system can be controlled. Among them, development and application of multifunction data processing software [29], digitized and initiative design of tooth surface [38-39], CNC programming and multi-axis CNC system development basing on the actual needs[40], secondary development basing on simulation processing platform[41], design of spiral bevel gears with high contact ratio[42]and other methods, will become flexible. More flexible is method, more prefect is function and field. In addition, using universal NC milling processing will promote the modeling more diversified [28, 41]. And using the theory of spherical involute completes fast accurate model of tooth surface, will have methods more colorful [5, 7

9th International Conference on Fracture & Strength of Solids June 9-13, 2013, Jeju, Korea 15, 25].

4. Conclusions
(1) Modeling technology by simulation process based on virtual reality has become the mainstream of the research of modeling, and will be constantly deepen and developed. (2) Modeling of enough precision, efficiency, flexibility, will promote the manufacture technology of spiral bevel gears high precision, high efficiency, and high flexibility. (3) Comprehensive use of all kinds of related technologies in its field , independent research and development of system software, make the parametric modeling technology transform to digital , will be the crucial link with improving the level of digital manufacture. (4) Modeling methods and basic thoughts are summarized, and the future development direction are put forward, which will provide some approaches about fast and precise modeling of spiral bevel gears for later researchers. Acknowledgement The authors gratefully acknowledge the support of National Natural Science Foundation of China (50965017) for this study. References [1] Litvin F L, Wang A G, Handschuh. Computerized generation and simulation of meshing and contact of spiral bevel gears with improved geometry. Comput. Methods Appl. Mech. Engrg. 1998,158:35-64. [2] Litvin F L, Fuentes A, Hayasaka K. Design, manufacture, stress analysis, and experimental tests of low-noise high endurance spiral bevel gears. Mechanism and Machine Theory2006, 41(1):83118. [3] A. Fuentes, F.L. Litvin, B.R. Mullins, et al. Design and stress analysis of low-noise adjusted bearing contact spiral bevel gears, ASME Journal of Mechanical Design2002, 124:524-532. [4] Faydor L. Ltivin, Alfonso Fuentes, Qi Fan, et al. Computerized design, simulation of meshing, and contact and stress analysis of face-milled format generated spiral bevel gears. Mechanism and Machine Theory2002, 21:775-786. [5] Suh S H, Jih W S, Hong H D, et al. Sculptured surface machining of spiral bevel gears with CNC milling. International Journal of Machine Tools &Manufacture2001, 41:833-850. [6] Wang Yanzhong, Zhou Yunfei, Li Zuozhang, et al. Study on NC machining for spiral bevel gear based on the universal CNC machine tools with five-axis. China Mechanical Engneering2001, 12(8):903-906. [7] Qi Fan, Ron Dafoe. Gleason expert manufacturing system (GEMS) opens a new era for digitized manufacturing of spiral bevel and hypoid gears. World Manufacturing Engineering & Market2005, (4):87-93. [8] Li Jingcai. Study on basic applied technology in the process of digitized manufacturing for spiral bevel gear. Tianjin: Tianjin University, 2008, 6. [9] Wang Jun, Wang Xiaochun, Jiang Hong, et al. Measurement of tooth surface of spiral bevel gear. Chinese Journal of Mechanical Engineering2003, 39(6):15l-154. [10] Su Zhijian, Wu Xutang, Mao Shimin, et al. Design of hypoid gear tooth surface represented by non-uniform rational B-spline polynomial. Journal of XiAn Jiaotong University, 39(1):17-20. [11] Wang Yuqing, Wang Xiaolin, Liang Jian. Study and implementation on entity mathematical pattern of spiral bevel gears. China Mechanical Engneering2007, 18(14):1160-1163. [12] Faydor L. Ltivin, Alfonso Fuentes, Qi Fan, et al. An invariant approach for gear generation with supplemental motions. Mechanism and Machine Theory2007, (42):275-295. [13] Suh S H, Jung D H, Lee E S, et al. Modeling, Implementation and manufacturing of spiral bevel gears with crown. Advanced Manufacturing Technology2003, (21):775-786. [14] Ltivin F L, Seol I H, Kim D, et al. Kinematic and geometric models of gear drives. Trans. ASME Journal of Mechanical Design1996, 118(12):544-550. [15] Ji Zhenhai, Duan Jianzhong, Gu Jihua. OpenGL-based 3D parameterization model for involute spiral bevel gear. Journal of Engineering Design2009, 16(6):432-435. [16] Han Jiaying, Wang Taiyong, Li Qing, et al. Computer cutting simulation and deviation analysis of tooth surface for hypoid gears. Manufacturing Technology & Machine Tool2010, (1):112-115. [17] Lin Chungyunn, Tsay Chungbiau. Mathematical model of spiral bevel and hypoid gears manufactured by the modified roll method. Mechanism and Machine Theory1997, 32(2):121-136. [18] FAN Q. Computerized modeling and simulation of spiral bevel and hypoid gears manufactured by 8

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