Computerized Design, Simulation of Meshing and Stress Analysis of External Helical Gear Drives Based on Critical Control Points

Zhen Chen, Bo Lei, Ling Qin, Guoting Qiu and Alfonso Fuentes-Aznar
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Zhen Chen: School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan 430074, China
Bo Lei: School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan 430074, China
Ling Qin: Automotive Engineering School, Wuhan University of Technology, Wuhan 430070, China
Guoting Qiu: Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China
Alfonso Fuentes-Aznar: Department of Mechanical Engineering, Rochester Institute of Technology, Rochester, NY 14623, USA

Energies, 2022, vol. 15, issue 12, 1-20

Abstract: Helical gears are widely used in powertrain systems. The computerized design of a new type of non-generated external helical gears based on critical control points at the transverse tooth profile is presented. The entire tooth profile is divided into different parts including the active tooth profile and fillet by control points. Involutes, circular arcs and Hermite curves are defined between two critical control points and smoothly connected with each other at those control points. The parametric equations for the tooth surfaces are derived considering the position of the mentioned control points. The basic design parameters and equations of the geometric sizing are proposed. The contact patterns, variation of the maximum stresses and peak-to-peak level of loaded transmission errors for six cases of design of the proposed new geometry of helical gear drives are studied with two cases of traditional helical gear drives as a reference, including gears with and without micro-geometry modifications. One case of an external helical gear drive designed with a combination of a circular arc and an involute to form the active tooth profile for both the pinion and the gear shows a much lower maximum bending stress and similar lower peak-to-peak level of loaded transmission errors with respect to the other cases of design. The proposed design method of tooth profiles based on critical control points lays the foundation for the topological optimization of helical gear drives.

Keywords: control points; combined tooth profiles; topological structure; tooth contact analysis; stress analysis; powertrain system (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2022
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