High-performance tooth flank collaborative optimization model for spiral bevel and hypoid gears

The tooth flank collaborative optimization considering both geometric and loaded contact performances is an increasingly significant target in design and manufacturing for spiral bevel and hypoid gears. Recently, numerical loaded tooth contact analysis (NLTCA) is always an important access of mapping of the required performance evaluations and design variables. In addition to the conventional solution to NLTCA, an innovative discrete convolution and fast Fourier transformation (DC-FFT) method focusing on the micro-scale tooth flank topography is developed for high-performance spiral bevel and hypoid gears. Then, combining with accuracy and efficiency, a new top-rem tool modification is proposed to establish a new collaborative optimization model. Where, while the target flank can be prescribed by considering the user needs in the actual manufacturing, a small number of tool parameters are selected as the unknown design variables. It can significantly deal with the strong nonlinearity and coupling effect from the traditional modification and improve the optimization efficiency. Moreover, a top-rem tool modification is used as the optimization strategy to get a high optimization accuracy. The spiral bevel gear set from aerospace industrial applications is exercised to demonstrate the impact of the proposed collaborative optimization model on the tooth flank geometric and loaded contact performances.