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<p>The performance of a harmonic drive (HD) is significantly affected by its key components, including the wave generator (WG), flexspline (FS), and rigid wheel (RW) for their performance. This paper proposes the mathematical model of a novel tooth profile design, ETE (Ellipse arc—Tangent line—Ellipse arc), to enhance the tooth profile design flexibility and transmission performance for harmonic drives. The mathematical model of the cylindrical skiving cutter design is also established for the practical manufacture of FS and RW tooth surfaces. To achieve the desired tooth surfaces and better tooth contact performance, the cutter profile is modified, with the skiving motion adjustment in the tooth lengthwise direction to ease the taper effect on the FS cup. Besides that, the finite element method-multi-body dynamics (FEM-MBD) simulation is used to analyze the transmission errors and flex spline tooth surface stresses of various tooth profiles to evaluate performance differences. Furthermore, numerical examples are performed according to the developed models to validate the effectiveness of the gear meshing performance enhancement. In addition, the simulation results indicate that the contact stress position of the untrimmed FS is located at the tooth top at the rear end of the tooth length and changes after trimming. To the tooth flank contact, the maximum Von-Mises stress of the trimmed FS dropped by 762.3&#xa0;MPa (48.34%). The meshing contact rate significantly increases from 13.75% to 28.75%. These results verify that this trimming method can effectively reduce stress while improving the HD’s tooth contact ratio.</p>

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Enhancement of gear meshing performance for harmonic drives with novel ETE-profile teeth modified by skiving process

  • 期刊论文

  • 发表日期：

    2025年5月15日

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  • Van-Quyet Tran,
  • Khoe-Qui Le,
  • Yu-Ren Wu,
  • Yung-Han Du

摘要

The performance of a harmonic drive (HD) is significantly affected by its key components, including the wave generator (WG), flexspline (FS), and rigid wheel (RW) for their performance. This paper proposes the mathematical model of a novel tooth profile design, ETE (Ellipse arc—Tangent line—Ellipse arc), to enhance the tooth profile design flexibility and transmission performance for harmonic drives. The mathematical model of the cylindrical skiving cutter design is also established for the practical manufacture of FS and RW tooth surfaces. To achieve the desired tooth surfaces and better tooth contact performance, the cutter profile is modified, with the skiving motion adjustment in the tooth lengthwise direction to ease the taper effect on the FS cup. Besides that, the finite element method-multi-body dynamics (FEM-MBD) simulation is used to analyze the transmission errors and flex spline tooth surface stresses of various tooth profiles to evaluate performance differences. Furthermore, numerical examples are performed according to the developed models to validate the effectiveness of the gear meshing performance enhancement. In addition, the simulation results indicate that the contact stress position of the untrimmed FS is located at the tooth top at the rear end of the tooth length and changes after trimming. To the tooth flank contact, the maximum Von-Mises stress of the trimmed FS dropped by 762.3 MPa (48.34%). The meshing contact rate significantly increases from 13.75% to 28.75%. These results verify that this trimming method can effectively reduce stress while improving the HD’s tooth contact ratio.