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Bevel gear design: anlaysis and synthesis of geometry and tolerances

Jérôme Bruyère 
Abstract : As technology increases and performance requirements continually tighten, the cost and required precision of assemblies increase as well. The forging evolution enables us to realize bevel gear net shape. Therefore, this work focuses on the parametric and tolerance design optimization of bevel gear. The synthesis of bevel gear nominal model is based on geometrical properties and kinematic properties of spherical involute. To ensure a quality level of meshing, it is necessary to limit the geometrical variations which are due to the manufacturing process (tolerance analysis and tolerance synthesis). To achieve this, we establish a geometrical model which includes the deviations (form, orientation and position). This model enables the evaluation of the impact of these deviations on the kinematic behaviour. This evaluation is T.C.A. (Tooth Contact Analysis) is based on the simulation of tangency of tooth surfaces being in mesh. The tolerance analysis is based on TCA and Monte Carlo simulation which computes the probability that the product respects the requirements of the kinematic error, under given individual tolerances. Moreover, to optimize the ratio of tolerance cost (tolerance synthesis) on probability that the product respects the requirements, genetic algorithm is improved. These tolerance analysis and synthesis do not take into account the teeth distortions. To do so, we propose to integrate the distortions which are evaluated by the influence coefficient method. Contact problem and bending problem of teeth are delinked. The contact influence coefficients are estimated by Boussinesq and Cerruti method. The bending influence coefficients are evaluated by interpolation and finite elements method. This model allows gearing analysis under load but the calculation time is a handicap for tolerance analysis. This behaviour models may be refined in future works and support the new geometrical specification models, process control and better knowledge of geometry-mechanic-material interaction.
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Submitted on : Monday, March 19, 2007 - 8:00:00 AM
Last modification on : Friday, October 23, 2020 - 4:38:07 PM
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  • HAL Id : pastel-00002262, version 1



Jérôme Bruyère. Bevel gear design: anlaysis and synthesis of geometry and tolerances. Engineering Sciences [physics]. Arts et Métiers ParisTech, 2006. English. ⟨NNT : 2006ENAM40⟩. ⟨pastel-00002262⟩



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