A method for the determination of optimal tooth modifications in spiral bevel gears based on improved load
distribution, minimized tooth root stresses and reduced transmission errors is presented. The modifications
areintroduced intothepinion tooth surfacebythevariation ofmachinetool settings in pinion tooth processing.
The applied load distribution and transmission error calculations are based on a new idea: As the tooth
surface modifications are relatively small and the conjugation of the mating surfaces is relatively good, it is
assumed that the point contact under load spreads over a surface along the whole or part of the “potential”
contact line, which line is made up ofthe points ofthe mating teeth surfaces in which the separations ofthese
surfaces are minimal, instead ofassuming an elliptical contactpattern. This method includes the bending and
shearing deflections of gear teeth, local contact deformations of mating surfaces, gear body bending and
torsion, deflections ofthe supporting shafts, and the manufacturing and alignmenterrors ofmating members.
A computer program implements the method.
By using the computer program that was developed the influence of machine tool settings for pinion tooth
manufacture on load distribution, stresses and transmission errors is investigated. On the basis of the
obtained results the optimal machine tool settings are determined introducing theoptimal tooth modifications.
By applying this optimal set of machine tool setting parameters the maximum tooth contact pressure is
reduced by 5.42%, the tooth fillet stresses in the pinion by 8.07% and the angular position error of the driven
gear by 48.43%, in regard to the spiral bevel gear pair manufactured by machine tool settings determined by
the commonly used method.

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