Computerized design, simulation of meshing, and contact and stress analysis of face-milled formate generated spiral bevel gears

A new approach for design, tooth contact analysis (TCA) and stress analysis of formate generated spiral bevel gears is proposed. The advantage of formate generation is the higher productivity. The purposes of the proposed approach are to overcome difficulties of surface conjugation caused by formate generation, develop a low noise and stabilized bearing contact, and perform stress analysis. The approach proposed is based on application of four procedures that enable in sequence to provide a predesigned parabolic function of transmission errors with limited magnitude of maximal transmission errors, a bearing contact with reduced shift of contact caused by misalignment, and perform stress analysis based on application of Finite Element Method. The advantage of the approach developed for finite element analysis (FEA) is the automatic generation of finite element models with multi-pairs of teeth. The stress analysis is accomplished by direct application of ABAQUS. Intermediate auxiliary CAD computer programs for development of solid models are not required. The theory developed is illustrated with an example of design and computation.