Design method for controlling gear surface cutting textures to reduce noise

To address the issue of cutting textures formed on gear tooth surfaces during the manufacturing process, a design method is proposed where the cutting textures are distributed according to a sine function. Initially, a simplified mathematical model of the actual gear tooth surface cutting texture was constructed based on a four-axis machining center and cylindrical milling cutter. Ten design cases were created with different sine function phases, aiming to minimize angular acceleration. These cases were compared with normally processed gear pairs to identify the optimal design. Subsequently, using the established actual tooth surface model, the optimal design gear pair was compared with normally processed gear pairs through noise simulation experiments. The correctness of the simulation results was verified through vibration and noise testing experiments. The results indicated that the maximum amplitude of the first-order frequency of vibration and noise sound pressure levels decreased by 14.93% and 11.16%, respectively, validating the effectiveness of the surface cutting texture optimization method. This method provides a novel solution for reducing vibration and noise in gears.