Influence of cut parameters on mesh performance of spiral bevel gear by duplex spread blade method

Spiral bevel gears are key components in many mechanical transmission systems, and their production is always of great interest to industry, and hence, subjected to intensive research widely. The present machining methods for manufacturing spiral bevel gears, including the so called five-cut method and completing method, have drawbacks such as low processing efficiency, requiring complex calculations and high requirements on the machine-tool performance, respectively. To solve the above problems, the duplex spread blade method is proposed. Firstly, geometric parameters and machine setting parameters were comprehensively considered, and then a modified reference point was selected to deduce the machine setting parameters. Tooth contact analysis (TCA) model considering misalignment was established to check meshing performance, the influence of cutter parameters and misalignment on meshing performance was studied. As the research reveals that the cutter radius has an effect on the bias of contact trace, cutter number has an impact on the position of contact pattern. The experimental results are consistent with the theoretical which verified the effectiveness and feasibility of the proposed method. The results of this paper have a guiding significance and enrich the machining method for spiral bevel gear.