Research On Meshing Performance Optimization Method Of Hypoid Gear With HGDH Method

The hypoid gear pair of automobile drive axles is gradually developing towards high speed and heavy load,and the vibration,impact noise and other problems caused in the transmission process are increasingly prominent,which has become the main reason for restricting the meshing performance of the gear pair.First of all,the gear pair is prone to elastic deformation under the conditions of high load,and the contact pattern of the tooth surface deviates from the theoretical meshing position.Secondly,the machining and assembly errors are prone to make the contact characteristics deviate from the ideal design results.All of the above problems make the gear easy to wear and produce strong impact and unsmooth transmission during the teeth pair conversion,which affects the meshing performance of the gear pair.With the continuous improvement of people’s demand for high-performance mechanical equipment,higher technical requirements are put forward for gear transmission performance.Therefore,this paper investigates the meshing performance for hypoid gear with gear cut by the generating method and pinion cut by the duplex helical method,namely the HGDH method,which is a further optimize of the tooth contact pattern based on the existing technology to reduce the meshing impact and achieve the purpose of reducing the vibration and noise,and is of great important significance for engineering application of hypoid gears,and the main contents of this paper are as follows:(1)Firstly,the mathematical model of a straight linear blade profile is deduced by the principle of coordinate transformation.Secondly,by analyzing the spatial relative position and motion relationship between the workpiece,the machine tool,and the cutter head,the mathematical model of gear cutting is established by vector method,and the tooth surface equation of the hypoid gear is obtained.Finally,based on the standard of tooth surface division,the tooth surface is divided,and a calculation program is written in Matlab to solve the multivariate nonlinear equations by the method of the tooth surface rotation projection,and the point cloud and the unit normal vector of the tooth surface are obtained,which are imported into UG to establish the 3D solid model of hypoid gear pair.(2)First of all,to analyze the spatial meshing theory,the assembly mathematical model of the hypoid gear generated by the completing method is established,and the contact characteristics of gear pairs with various installation errors are discussed.In the second place,the mathematical model of tooth surface topology is established,and the modification principle of helical motion coefficient on the concave and convex surfaces of the pinion and the influence law of helical motion coefficient on tooth surface geometry is analyzed.In the end,the principle of generating curve solution is expounded,and the influence between the helical motion coefficient and the position of generating curve of tooth surface is studied,which provides references for studying the relationship between the micro-morphology of the tooth surface and the meshing impact and noise of the gear.(3)Design a sinusoidal blade profile with 4 blade profile parameters(BPPs),and the relationship between the BPPs and the tooth surface mismatch is analyzed.In addition,4 design cases(gear,pinion,and both manufactured by sinusoidal blade profile)are analyzed and compared by using the Tooth Contact Analysis(TCA)and finite element analysis method(FEM),and the influence of sinusoidal profile modification on transmission amplitude,contact stress and other meshing characteristics are studied.The results show that the sinusoidal blade profile can achieve the tooth profile modification to avoid edge contact,and uneven distribution of the tooth surface load,and effectively reduce the tooth surface contact stress.(4)Considering the impact of meshing in and meshing out of hypoid gears,the mathematical model of low-impact optimization of the tooth surface is established.A global optimization method of hypoid gear meshing performance is proposed,which preset the contact characteristics of the tooth surface,takes the feasible region of BPPs as the constraint,and takes the minimum peak value of the relative motion angular acceleration of the tooth surface as the objective function.The best BPPs are calculated by the trust-region reflection algorithm.The results show that the minimum relative motion angular acceleration of the gear pair machined by the optimized BPPs decreases during meshing,the contact pattern meets the requirements,the noise decreases,and the meshing process of the gear pair is more stable.(5)2 groups of cases are designed,and the gear dynamic model is established based on the software Adams for simulation analysis.The time domain and frequency domain diagrams of the angular acceleration of the centroid of the gear under the forward and reverse driving conditions of the 2 cases are obtained,which verifies that the sinusoidal blade profile can achieve the effect of vibration reduction and noise reduction.Taking a hypoid gear 7×43 as a case,through the machining and rolling test of the completing method,which verifies the feasibility of sinusoidal profile modification to reduce vibration and noise and the correctness of the optimization model.