Enhanced Algorithms of Contact Simulation for Hypoid Gear Drives Produced by Face-Milling and Face-Hobbing Processes

Modeling of tooth surface generation and simulation of contact is an important part of computerized design and manufacturing of spiral bevel and hypoid gears. This paper presents new developments in this subject. Specifically, the paper covers: (i) development of a generic model of tooth surface generation for spiral bevel and hypoid gears produced by face-milling and face-hobbing processes conducted on free-form computer numerical control (CNC) hypoid gear generators which are incorporated with the Universal Motions Concept (UMC); (ii) a modified algorithm of tooth contact simulation with reduced number of equations of the nonlinear iterations and stabilized iteration convergence; and (iii) an algorithm of numerical determination of contact lines that form the contact patterns. The enhanced approach of contact simulation can be generally applied to other forms of gearings. Two examples, a face-hobbing design and a face-milling design, are illustrated to verify the implementation of the developed algorithms.