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A novel computerized approach for the design and generation of face-milled non-generated hypoid gears with the cutter tilt method in non-orthogonal configuration has been proposed. A new method for pitch cone and gear blank design based on two mathematical iterations has been proposed for hypoid gears in non-orthogonal shaft angle configurations. A calculated methodology of machine-tool settings for both pinion and wheel has been developed based on the local synthesis method. An accurate mathematical model of the tooth surface geometry for hypoid gears in non-orthogonal configurations has been established. An approach for selecting the required geometric parameters is established to avoid the low-quality of gear surface such as undercutting or pointing of the top land. A simulation of the mesh behavior of hypoid gear surface has been performed based on the checked design parameters by two numerical examples of low and obtuse crossed shaft angle configurations. The results show that the mesh behavior and geometries of gear surface verify well with preset contact parameters and design parameters.

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Computerized Design Methodology and Meshing Behavior Controlling Technology of Face-Milled Hypoid Gear in Non-orthogonal Configuration

  • 会议论文

  • 发表日期：

    2026年

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  • Jingwei Pang,
  • Siyuan Liu,
  • Chaosheng Song,
  • Caichao Zhu,
  • Wenjun He,
  • Hailan Song

摘要

A novel computerized approach for the design and generation of face-milled non-generated hypoid gears with the cutter tilt method in non-orthogonal configuration has been proposed. A new method for pitch cone and gear blank design based on two mathematical iterations has been proposed for hypoid gears in non-orthogonal shaft angle configurations. A calculated methodology of machine-tool settings for both pinion and wheel has been developed based on the local synthesis method. An accurate mathematical model of the tooth surface geometry for hypoid gears in non-orthogonal configurations has been established. An approach for selecting the required geometric parameters is established to avoid the low-quality of gear surface such as undercutting or pointing of the top land. A simulation of the mesh behavior of hypoid gear surface has been performed based on the checked design parameters by two numerical examples of low and obtuse crossed shaft angle configurations. The results show that the mesh behavior and geometries of gear surface verify well with preset contact parameters and design parameters.