This paper presents an automatic procedure to optimize the loaded tooth contact pattern of face-milled hypoid gears with misalignments varying within prescribed ranges. A two-step approach is proposed to solve the problem: in the first step, the pinion tooth microtopography is automatically modified to bring the perturbed contact patterns (as the assembly errors are varied within the tolerance limits) match a target area of the tooth while keeping them off the edges; in the second step, a subset of the machine-tool settings is identified to obtain the required topography modifications. Both steps are formulated and solved as unconstrained nonlinear optimization problems. While the general methodology is similar to the one recently proposed by the same authors for the optimization at nominal conditions, here, the robustness issues with respect to misalignment variations are considered and directly included in the optimization procedure: no a posteriori check for robustness is therefore required. Numerical tests show that nominally satisfactory and globally robust hypoid pairs can be designed by a direct process and within a unified framework, thus avoiding tiresome trial-and-error loops.
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e-mail: m.gabiccini@ing.unipi.it
e-mail: a.bracci@ing.unipi.it
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April 2010
Research Papers
Robust Optimization of the Loaded Contact Pattern in Hypoid Gears With Uncertain Misalignments
M. Gabiccini,
M. Gabiccini
Dipartimento di Ingegneria Meccanica, Nucleare e della Produzione,
e-mail: m.gabiccini@ing.unipi.it
University of Pisa
, Via Diotisalvi 2, 56122 Pisa, Italy
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A. Bracci,
A. Bracci
Dipartimento di Ingegneria Meccanica, Nucleare e della Produzione,
e-mail: a.bracci@ing.unipi.it
University of Pisa
, Via Diotisalvi 2, 56122 Pisa, Italy
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M. Guiggiani
M. Guiggiani
Dipartimento di Ingegneria Meccanica, Nucleare e della Produzione,
e-mail: m.guiggiani@ing.unipi.it
University of Pisa
, Via Diotisalvi 2, 56122 Pisa, Italy
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M. Gabiccini
Dipartimento di Ingegneria Meccanica, Nucleare e della Produzione,
University of Pisa
, Via Diotisalvi 2, 56122 Pisa, Italye-mail: m.gabiccini@ing.unipi.it
A. Bracci
Dipartimento di Ingegneria Meccanica, Nucleare e della Produzione,
University of Pisa
, Via Diotisalvi 2, 56122 Pisa, Italye-mail: a.bracci@ing.unipi.it
M. Guiggiani
Dipartimento di Ingegneria Meccanica, Nucleare e della Produzione,
University of Pisa
, Via Diotisalvi 2, 56122 Pisa, Italye-mail: m.guiggiani@ing.unipi.it
J. Mech. Des. Apr 2010, 132(4): 041010 (8 pages)
Published Online: April 22, 2010
Article history
Received:
May 29, 2009
Revised:
November 16, 2009
Online:
April 22, 2010
Published:
April 22, 2010
Citation
Gabiccini, M., Bracci, A., and Guiggiani, M. (April 22, 2010). "Robust Optimization of the Loaded Contact Pattern in Hypoid Gears With Uncertain Misalignments." ASME. J. Mech. Des. April 2010; 132(4): 041010. https://doi.org/10.1115/1.4001485
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