Computerized Design of Straight Bevel Gears with Optimized Profiles for Forging, Molding, or 3D Printing

摘要

The involute profile is the most commonly used tooth profile for cylindrical gears. Gears with involute profiles are not sensitive to center distance variations, and they are easy to manufacture. In this work, the spherical involute profile, considered the counterpart of the involute profile for bevel gears, is derived and applied for straight-tooth bevel gears. The computerized generation of straight bevel gears with spherical involute profiles will be developed and the advantages of its application investigated. Spherical involute profiles might be applied for bevel gears manufactured by forging, molding, or 3D printing. Possible micro-geometry modifications of the gear tooth surfaces are also investigated in order to provide stable contact patterns when errors of alignment occur. Finally, finite element analysis is applied in order to determine the contact and bending stresses and investigate the load transfer and contact pattern evolution under load. A complete example of design and simulation of straight bevel gears with the spherical involute profile is provided.