Lapping adjustment method for actual surface of hypoid gears

Due to flank deformation induced by the heat treatment and manufacturing error in previous cutting, the lapping position on the gear surface would deviate from the theoretical ones, which would lead to the reduction of lapping quality. In this paper, the lapping adjustment method of the actual surface of hypoid gear is proposed. Firstly, a bi-cubic B-spline surface is applied to reconstruct and densify the meshing flanks based on the measured tooth flank form data. Secondly, a discrete tooth contact analysis (DTCA) approach is introduced to calculate the real lapping position. A dynamic two-dimension golden section iteration algorithm is used to obtain the exact meshing location. In the end, a hypoid gear set after heat treatment is selected to perform the rolling test. The results from the lapping position calculation method is according with the rolling test results, by which the effectiveness and feasibility of the proposed algorithm are confirmed.