2212 A New Design and Analysis System for Hypoid Gears

Usually the design of hypoid gear is more difficult than helical gear because it uses different theoretical tooth flank that is described by individual machine setting and cutter specification for each gear. This research developed a new design and analysis system for both of face-mill and face-hob type hypoid gears. The new design system consists of five parts: (1) basic dimension calculation, (2) cutting machine setting, (3) simulation of 3-D theoretical tooth flank, (4) TCA of theoretical tooth flank, (5) Real TCA of actual tooth flank. The machine setting of this paper based on the basic relationship between the pitch cones and assembly dimensions, is compatible to the conventional Gleason system. Especially, the analyzed tooth contact pattern of the soft tooth flank just after cutting or the lapped hard tooth flank after heat-treatment agreed well to each measured result, respectively.