Meshing Simulation And Fatigue Analysis Of The Cylindrical Gear Based On The Hobbing Principle

Lightweight is an important direction for the development of the current equipment manufacturing industry.Reducer as a basic component of various mechanical equipments has a crucial role on the machine's lightweight. The gear transmission mechanism is the core part of the reducer, which is widely used by cylindrical gear drive. To achieve the lightweight design of the reducer, we must achieve the meshing simulation and fatigue analysis of cylindrical gear drive firstly.The meshing simulation and fatigue analysis of gear model is the base of gear lightweight design. The reliability of the strength analysis results depends on the correctness of the analysis method and the accuracy of the model. The meshing of the gear pair is non-linear and finite element transient meshing analysis can effectively solve non-linear problem. The accuracy of the gear model depends on the accuracy of the tooth surface, which directly affects the accuracy of the analysis results, so the precise modeling of the tooth surface is the premise of the lightweight design.Hobbing processing with the features of continuous processing and high efficiency is the most commonly method to processing cylindrical gear. Aiming at the lightweight design and optimization of cylindrical gears, a new technique of precise modeling for cylindrical gears was proposed based on the hobbing principle.According to the spatial meshing principle and general parametric equations of hob cutting surface, a system of general tooth surface equations of cylindrical gear was derived. Then the parameter equations of the hob cutting surfaces of Archimedes gear hob which is widely used to processing gear were deduced by using the standard structural parameters through selecting from the national standard of Archimedes gear hob. Accurate tooth surface of cylindrical gear was built by B-spline surface interpolation. Then established a simplified cylindrical gear single tooth model,arrayed to obtain the multi-tooth model after mapping the mesh, a simplified finite element assembly model of gear pair was established by no side seam assembly.Transient engagement analysis is a continuous static analysis of multiple meshing positions.It is a kind of method to study the stress variation process of gear teeth during meshing in order to obtain the maximum stress of gears. In this paper,the transient analysis of the gear pair was realized by the simulation analysis function of ANSYS software, and the stress level and meshing characteristics of the gear pair in any position were simulated and obtained by simulation example. The comparison with other modeling methods showed that the method can realize the accurate modeling of cylindrical gears and illustrates the importance and necessity of the modeling method.On the basis of hobbing principle, the influence of different machining elements on the gear strength was anaylized. In addition, this paper studied the hobbing process and the gear tooth profile with the billet eccentric installation based on the hobbing principle. The influence of the eccentricity on the gear strength was studied by meshing analysis of the three special positions of the eccentric gear pair and the non-eccentric gear pair. The results showed that the stress level of any of the meshing positions after eccentric installation is improved.Fatigue analysis is the most direct study on whether the design gear pair can achieve the design fatigue life. The fatigue life curve was obtained by the stress cycling characteristic of the gear pair. The fatigue life analysis of the corresponding maximum stress position of the gear pair was carried out. The minimum safety factor of analysis results is the safety factor of the gear pair.