Funktionsorientierte Auslegung topologischer Zahnflankenmodifikationen für Beveloidverzahnungen

The aim of this thesis at hand is to develop a method for the function-oriented design of topological tooth flank modifications for beveloid gears. In particular, the analysis of the manufacturability of the topological tooth flank modifications is integrated into the design method. The analysis is based on a manufacturing simulation combined with a dressing simulation to illustrate the diagonal generating gear grinding process. The result of the manufacturing simulation represents the three-dimensional description of the tooth gap. This description is used as an input variable for an FE-based tooth contact analysis. With its help, the operational behavior under load is determined. Both simulations are linked by an optimization method. The topological tooth flank modification that is determined can be manufactured, is robust against deviations from the target topography and improves the operational behavior of the beveloid gear. The optimization method is accelerated by the use of meta modeling techniques which results in a better coverage of the parameter space and consequently allows a time-efficient determination of the global optimum. In the first step, suitable methods for the geometrical description of the topological tooth flank modifications are designed. In doing so two descriptions are developed – one being based on a two-dimensional polynomial and the other one based on spline functions which are defined by a support grid. In the second step, the manufacturing simulation is extended by a dressing simulation and an enhanced description of the process kinematics. In the dressing simulation both form and profile dressers can be used for dressing the grinding worm. The manufacturing simulation is successfully applied to beveloid gears as well as cylindrical gears and is validated by grinding tests on a helical gear. When comparing simulation and test a high degree of correspondence both in quality and quantity becomes obvious. The third step deals with the application of the design method. First, the potential of topological tooth flank modifications to improve the operational behavior of beveloid gears is determined simulatively with an FE-based tooth contact analysis. Subsequently, a suitable test gear is designed and three different variants of microgeometry modifications are identified. The topological tooth flank modification shows the lowest excitation behavior. The design method also considers the sensitivity of the topological tooth flank modifications within the manufacturing process. Then the gears are manufactured by using a five-axis milling process. The comparisons of transmission error and the contact pattern show a high correspondence between simulation and test. The FE-based tooth contact analysis can therefore be successfully validated for topological tooth flank modifications. With the method developed in this thesis at hand a validated approach for the design of topological tooth flank modifications is available. The method can be applied to beveloid gears as well as to cylindrical gears. In particular, the approach of the sensitivity analysis for manufacturing deviations for topological tooth flank modifications represents a novelty compared to existing design methods