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外文资料--EXPERIMENTAL VALIDATION OF A COMPUTERIZED TOOL FOR FACE HOBBED GEAR CONTACT AND TENSILE STRESS ANALYSIS.pdf

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外文资料--EXPERIMENTAL VALIDATION OF A COMPUTERIZED TOOL FOR FACE HOBBED GEAR CONTACT AND TENSILE STRESS ANALYSIS.pdf

SPITRANTRUCPROCESSESFACKNGLEASOEMPRODECADECOCUTTERSUCCESSLOTMANYSTUDIESABOUTTOOTFMONTHECMOTHEOPPROCEEDINGSOFTHEASME2007INTERNATIONALDESIGNENGINEERINGTECHNICALCONFERENCESCOMPUTERSANDINFORMATIONINENGINEERINGCONFERENCEIDETC/CIE2007SEPTEMBER47,2007,LASVEGAS,NEVADA,USA1COPYRIGHT2007BYASMEIONRALBEVELANDHYPOIDGEARDRIVESAREWIDELYAPPLIEDINTHESMISSIONOFMANYAPPLICATIONS,SUCHASHELICOPTERS,CARS,KS,ETCTHEYAREMANUFACTUREDUSINGMAINLYTWOCUTTINGEMILLINGORFACEHOBBINGMETHODASWELLOWN,FACEMILLINGPROCESS,TRADITIONALLYADOPTEDBYTHENWORKS,UTILIZESACIRCULARFACEMILLTYPECUTTERANDPLOYSANINTERMITTENTINDEXONTHECONTRARY,DURINGFHCESS,TRADITIONALLYADOPTEDBYOERLIKONANDINTHELASTSBYTHEGLEASONWORKSASWELL,THEWORKHASNTINUOUSROTATIONANDROTATESINATIMEDRELATIONSHIPWITHTHESIVECUTTERBLADEGROUPSENGAGESSUCCESSIVETOOTHSASTHEGEARISBEINGCUT1HSURFACEREPRESENTATIONANDDESIGNOFSPIRALBEVELANDHYPOIDGEARSHAVEBEENCARRIEDOUT25ONTRARY,ABOUTFHPROCESS,THATISTHECONSIDERABLYRECOMPLEX,ONLYASMALLNUMBEROFWORKSAREAVAILABLEINENLITERATURE67PINIONGEARMODULEMM494OFFSETMM0SHAFTANGLE90TEETHNUMBER1236MEANSPIRALANGLE35000HANDLHRHFACEWIDTHMM254MEANCONEDISTANCEMM8105NOMINALPRESSUREANGLE225THEMODELVALIDATIONREQUIRESTHEFOLLOWINGSTEPSSTARTINGFROMTHEINFORMATIONSTOREDINTABLE1,BYMEANSOFACOMMERCIALGEARDESIGNSOFTWARE,THEGEOMETRICPARAMETERS,THEBASICMACHINESETTINGSANDTHECUTTINGBLADEDATAWILLBEFIRSTLYCOMPUTED;AFTERTHAT,BYMEANSOFTHEPROPOSEDMODEL,EXPERIMENTALVALIDATIONOFACOMPUTCONTACTANDTENSILESTRESSANALANDREAPIAZZAANDREAPIAZZACRFITPOWERTRAINRESEARCHANDTECHNOLOSTRADATORINO5010043OABSTRACTWHILEFACEMILLEDGEARSHAVEBEENWIDELYANALYZED,ABOUTFACEHOBBEDONESONLYVERYFEWSTUDIESHAVEBEENDEVELOPEDANDPRESENTEDGOALOFTHISPAPERISTOPROPOSETHEVALIDATIONOFANACCURATETOOL,WHICHWASPRESENTEDBYTHEAUTHORSINPREVIOUSWORKS,AIMEDTOTHECOMPUTERIZEDDESIGNOFFACEHOBBEDGEARSFIRSTLY,THEMATHEMATICALMODELABLETOCOMPUTEDETAILEDGEARTOOTHSURFACEREPRESENTATIONONBOTHSPIRALANDHYPOIDGEARSWILLBEBRIEFLYRECALLED;THEN,THESOOBTAINED3DTOOTHGEOMETRYISEMPLOYEDASINPUTFORANADVANCEDCONTACTSOLVERTHAT,USINGAHYBRIDMETHODCOMBININGFINITEELEMENTTECHNIQUEWITHSEMIANALYTICALSOLUTIONS,ISABLETOEFFICIENTLYCARRYOUTBOTHCONTACTANALYSISUNDERLIGHTORHEAVYLOADSANDSTRESSTENSILECALCULATIONTHEVALIDATIONANALYSESWILLBECARRIEDONPUBLISHEDAEROSPACEFACEHOBBEDSPIRALBEVELGEARDATACOMPARINGMEASUREMENTSOFROOTANDFILLETSTRESSESGOODAGREEMENTWITHEXPERIMENTALRESULTSBOTHINTHETIMESCALEANDINMAGNITUDEWILLBEREVEALED1INTRODUCTERIZEDTOOLFORFACEHOBBEDGEARYSISMARTINOVIMERCATIGY–CENTRORICERCHEFIATRBASSANOTO,ITALYTHEAUTHORSOFTHISPAPERHAVEWORKEDEXTENSIVELYONTHATTOPICPROPOSINGAMATHEMATICALMODELAIMEDTOTHECOMPUTATIONOFTHEFACEHOBBEDGEARTOOTHSURFACES8;MOREOVERTHEYHANDLEDTHEOUTPUTOFTHISMODELINORDERTOCARRYOUTACOMPUTERIZEDDESIGNOFTHESEGEARS9GOALOFTHISPAPERISTOPROVIDETHEVALIDATIONOFTHATTOOLTOTHISEND,ACOMPARISONWITHEXPERIMENTALDATAWILLBEPROPOSED;INPARTICULARTHERESULTSCOLLECTEDBYHANDSCHUHETAL10WILLBECONSIDEREDINTHATREFERENCEANEXPERIMENTALEVALUATIONOFTHEPERFORMANCEOFANAEROSPACESPIRALBEVELFACEHOBBEDGEARDRIVE,INTHEFOLLOWINGNAMEDTEST,ISSHOWNINDETAIL,RESULTSINTERMSOFLOADEDTOOTHCONTACTANALYSIS,STRESSCALCULATIONANDVIBRATION/NOISEMEASUREMENTAREWIDELYDISCUSSEDTHEBASICCHARACTERISTICSOFTHETESTGEARDRIVEARESUMMARIZEDINTABLE1TABLE1BASICCHARACTERISTICSOFTHETESTGEARDRIVEDETC200735911THEGEOMETRYOFTHETOOTHCANBECALCULATEDANDTHEGEARDRIVEPERFORMANCEUNDERLOADCANBEEVALUATEDTHEMAINEFFORTISDEVOTEDJUSTTOVALIDATETHEMODELBYCOMPARINGTHESTRESSESEXPERIMENTALLYMEASUREDINTHEROOTANDINTHEFILLETAREAWITHTHEONENUMERICALLYCALCULATED;AQUALITATIVECOMPARISONOFTHELOADEDTOOTHCONTACTPATTERNWILLBEALSOPROVIDED2MODELDESCRIPTIONANDMETHODOFTHETABLE2TOOTHGEOMETRYDATAOFTHETESTGEARDRIVEPINIONGEARMODULEMM4941OFFSETMM0SHAFTANGLE90TEETHNUMBER1236ANALYSISTHEFIRSTSTEPINORDERTOBUILDARELIABLENUMERICALMODELISTOGETAFINEGEOMETRICALREPRESENTATIONOFGEARTOOTHSURFACESTHISISESPECIALLYTRUEWHENONEISDEALINGWITHCOMPLEXTOOTHGEOMETRYSUCHASTHEFACEHOBBINGONETOTHISAIM,ASERIESOFALGORITHMSABLETOCOMPUTETOOTHSURFACESOFFHGEARSSTARTINGFROMCUTTINGPROCESSHASBEENIMPLEMENTEDBYTHEAUTHORS8THEGEOMETRYOFREALFHHEADCUTTERGLEASONTRIACISCONSIDERED;MANYKINDSOFBLADECONFIGURATIONSTRAIGHTANDCURVEBLADES,WITHORWITHOUTTOPREMARETAKENINTOACCOUNTTHEN,ACCORDINGTOTHETHEORYOFGEARING11,FHCUTTINGPROCESSWITHANDWITHOUTGENERATIONMOTIONISSIMULATEDANDGEARTOOTHSURFACESEQUATIONSCANBECOMPUTEDTHEPROPOSEDMATHEMATICALMODELISABLETOPROVIDEANACCURATEDESCRIPTIONOFTHEWHOLETOOTH,INCLUDINGFILLETREGION;ITALSOCONSIDERSUNDERCUTTINGOCCURRENCE,WHICHISVERYCOMMONINFHGEARSDUETOUNIFORMDEPTHTOOTHTHEOBTAINEDTOOTHSURFACESAREUSEDASFUNDAMENTALINPUTFORAPOWERFULCONTACTSOLVERWHICHISBASEDONASEMIANALYTICALFINITEELEMENTFORMULATION1213THEGEARDRIVECANBESTUDYUNDERLIGHTLOADBYMONITORING,FORDRIVEANDCOASTSIDE,THECONTACTPATTERNANDTRANSMISSIONERRORIEITCANBEPERFORMEDTHECOMMONLYCALLEDTOOTHCONTACTANALYSIS–TCA14MOREOVER,WITHTHEAIMTOFINDOUTGEARDRIVEPERFORMANCEINTHEREALSERVICECONDITIONS,ASETOFTORQUEVALUESCANBEAPPLIEDANDTHEINFLUENCEOFTHELOADONCONTACTPATTERN,ONTRANSMISSIONERRORANDONLOADSHARINGCANBEACCURATELYANALYZEDLOADEDTOOTHCONTACTANALYSIS–LTCA15CONTACTPRESSUREANDSTRESSDISTRIBUTIONCANBEALSOEASILYEVALUATED2GEOMETRICANDMANUFACTORINGOFTHETESTGEARDRIVEUSINGTHEDATACOLLECTEDINTABLE1ASPRELIMINARYINPUTFORACOMMERCIALSOFTWAREFORGEARDESIGNGLEASONT2000,ACALCULATIONAIMEDTOREPRODUCETHETESTGEARDRIVEHASBEENATTEMPTEDTABLE2DESCRIBESTHEOBTAINEDTOOTHGEOMETRY;TABLE3AND4SHOWTHEDETAILSREGARDINGTHEMACHINESETTINGANDTHECUTTINGBLADESTHEPINIONISGENERATEDANDTHEGEARISFORMATE;BOTHTHEMEMBERSARECUTBYMEANSOFCURVEDBLADESUSINGAHEADCUTTERWITHNOMINALRADIUSEQUALTO76MMAND13BLADEGROUPS2COPYRIGHT2007BYASMEMEANSPIRALANGLE3500035000HANDLHRHFACEWIDTHMM254254OUTERCONEDISTANCEMM9374393743PITCHANGLE1843571565ADDENDUMMM49302067DEDENDUMMM29425805TABLE3BASICMACHINESETTINGSFORTHETESTGEARDRIVEPINIONGEARCONCAVECONVEXCONCAVECONVEXGENERATEDFORMATERADIALSETTINGMM91451914519236492364TILTANGLE2009920099SWIVELANGLE2537125371BLANKOFFSETMM00000000MACHINEROOTANGLE015401547156571565MACHINECENTERTOBACKMM007220072215091509SLIDINGBASEMM1386513865CRADLEANGLE53697498175140551405RATIOOFROLLMM29992999TABLE4CUTTINGBLADESDATAFORTHETESTGEARDRIVEPINIONGEAROBIBOBIBBLADETYPECURVEDCURVEDCURVEDCURVEDBLADERADIUSMM75499757587620675749BLADEECCENTRIC17832176331773817846BLADEHEIGHTMM4363436343744374BLADEANGLE25323181222223121681BLADEGROUPSNUMBER13131313NOMINALRAKEANGLE12000120001200012000HOOKANGLE4420442044204420CUTTEREDGERADIUSMM0700070010001000BLADERADIUSOFCURVATUREMM762000762000762000762000TOPREMANGLETOPREMLENGTHMM3TOOTHGEOMETRYOFTHETESTGEARDRIVEFIGURE1ILLUSTRATESTHETOOTHGEOMETRYREPRESENTATIONOBTAINEDDUETOTHEFACTTHATTHEREFERENCEDOESNOTPROVIDEANYTOPOLOGICALDATA,JUSTAQUALITATIVECOMPARISONBETWEENTHEREALTOOTHGEOMETRYANDTHEONECALCULATEDBYMEANSOFTHENUMERICALMODELISFEASIBLEFIGURE3BYMEANSOFTHEPROPOSEDMODELFORTHETESTGEARDRIVEFIGURE1TESTGEARTOOTHGEOMETRYREPRESENTATIONFIGURE2DESCRIBESTHEFILLETAREABYMEANSOFTHETRENDALONGTHEFACEWIDTHOFTHENOMINALROOTLINENRL,OFTHEREALROOTLINERRLANDOFTHEUNDERCUT/FILLETUC/FLLINEACCORDINGTOTHATPICTUREITISPOSSIBLETONOTETHETOOTHDOESNOTSHOWUNDERCUTFIGURE2DETAILSOFTHEFILLETAREA3COPYRIGHT2007BYASMEFIGURE3QUALITATIVECOMPARISONBETWEENTHEREALPINIONTOOTHGEOMETRYANDTHECALCULATEDONE31EVALUATIONOFACTUALTESTGEARFILLETRADIUSSTARTINGFROMTHEPICTUREOFTHEREALPINIONTOOTHFIGURE3–ABOVE,AROUGHMEASUREMENTOFTHERADIUSOFTHEFILLETHASBEENALSOATTEMPTEDDOINGTHISWAY,REFERRINGTOTHETOEOFTHECONCAVESIDE,AVALUEABOUTEQUALTO094MMISOBTAINEDWHENTHESAMEZONEOFTHENUMERICALLYCOMPUTEDTOOTHISCONSIDERED,AVALUEEQUALTO126MMINCORRESPONDENCEOFTHEMAXIMUMCURVATUREPOINTBETWEENTHEMIDDLEOFINNERSURFACEANDTHECONTACTSURFACEISEVALUATEDTHEDIFFERENCEMAYBEQUITELARGE34AND,ASITWILLBESHOWNLATER,THISEVIDENCEWILLHAVEASIGNIFICANTINFLUENCEONTHEFILLETSTATEOFSTRESSASKNOWNTHEFILLETRADIUSISSTRICTLYRELATEDTOTHEEDGERADIUSOFTHECUTTINGBLADETHEVALUEUSEDTOCUTTHEREALTOOTHISUNKNOWNWHILEINTHENUMERICALMODELITISASSUMEDTOBEEQUALTO07MMINORDERTOACHIEVEAFINERCORRESPONDENCE,MODELSCONSIDERINGOTHEREDGERADIUSVALUESHAVEBEENBUILTNAMELY,05MMAND03MMHAVEBEENTRIEDOBTAININGTHERESULTSSUMMARIZEDINTABLE5ANDFIGURE4THEPOINTSUSEDFORTHERADIUSCALCULATIONAREHIGHLIGHTEDITCANBENOTEDTHATUSINGANEDGERADIUSEQUALTO03MMTHEBESTCORRESPONDENCECANBEACHIEVEDTABLE5COMPARISONBETWEENTHEPHOTOMEASUREDANDTHENUMERICALFILLETRADIUSBYVARYINGEDGERADIUSSCHEMATIZATIONITISPOSSIBLETOAFFIRMTHATTHEHEELPOSITIONCORRESPONDSTOT05,THEMIDONETOT0ANDTHETOEONETOT05;THEROOTAREAISLOCATEDINTHERANGE0≤S≤2WHILETHECUTTEREDGERADIUSMMPINIONFILLETRADIUSMMPHOTOMEASUREDPINIONFILLETRADIUSMMDIFFERENCE07012609434040501100941702030098094426FIGURE4COMPARISONBETWEENTHENUMERICALPINIONCONCAVESIDEPROFILEANDTHEPHOTOMEASUREDONENOTETHATTHEREFERENCESYSTEMSAREDIFFERENT4STRESSCALCULATIONREFERRINGTOTHEEXPERIMENTALINVESTIGATION,THESTRESSESAREEVALUATEDBYMEANSOFSTRAINGAGESINTHEFILLETAREAINDETAIL,REFERRINGTOTHESKETCHDEPICTEDINFIGURE5,ONESTRAINGAGEATTHEHEELPOSITIONINTHEFILLETANDTHREESTRAINGAGESATHEEL,MIDANDTOEPOSITIONSINTHEROOTIEONTHEROOTCONEONTHEOTHERHAND,WITHTHEAIMTONUMERICALLYCOMPUTETHESTRESSES,ITISNECESSARYTODEFINEASETOFCOORDINATESWHICHAREABLETOSTRAIGHTFORWARDLYPROVIDETHESTRESSMEASURINGPOINTONTHETOOTHHERE,THECURVILINEARCOORDINATETWHICHRUNSALONGTHEFACEWIDTH1≤T≤1INFIGURE6AANDTHECURVILINEARCOORDINATESWHICHRUNSALONGTHETOOTHPROFILE0≤S≤48INFIGURE6BHAVEBEENDEFINEDACCORDINGTOTHIS4COPYRIGHT2007BYASMEFILLETONEINTHERANGE5≤S≤7FIGURE5SKETCHUSEDINTHETESTREFERENCEFORLOCATIONOFTHESTRAINGAGESFIGURE6ASCHEMATIZATIONFORDEFININGTHESTRESSMEASURINGSECTIONALONGTHEFACEWIDTHOFTHEMODELFIGURE6BSCHEMATIZATIONFORDEFININGTHESTRESSMEASURINGPOINTONAGENERICSECTIONOFTHEMODEL

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