Geometry and Parameter Design of Novel Circular Arc Helical Gears For
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Research Article Advances in Mechanical Engineering 2017, Vol. 9(2) 1–11 Ó The Author(s) 2017 Geometry and parameter design of DOI: 10.1177/1687814017690957 novel circular arc helical gears for journals.sagepub.com/home/ade parallel-axis transmission Zhen Chen1, Huafeng Ding1,BoLi1, Linbo Luo1, Liang Zhang2 and Jing Yang2 Abstract Based on the space curve meshing equation, in this article, a geometry design of a novel circular arc helical gear mechan- ism with pure rolling for parallel transmission was presented. Different from conventional circular arc gears, the meshing points of circular arc helical gears were limited at the instantaneous centre of rotation. The parameter equations describing the contact curves for both the driving gear and the driven gear were deduced from the space curve meshing equation, and parameter equations of the concave–convex circular arc profiles were established both for internal mesh- ing and external meshing. Furthermore, a formula for the contact ratio was presented, and the impact factors influencing the contact ratio were discussed. Then, the parameter design was presented for the geometry parameters of tooth pro- files, such as normal pitch, tooth height and tooth thickness. Using the deduced equations, several numerical examples were then considered, and prototype samples were produced to experimentally validate the contact ratio equation and the theoretical kinematic performance. The circular arc helical gear mechanism investigated in this study showed a high gear transmission performance such as a pure rolling meshing, a high contact ratio and a large comprehensive strength, when considering engineering applications. Keywords Pure rolling, geometry design, contact ratio, concave–convex meshing, space curve meshing equations Date received: 14 October 2016; accepted: 25 December 2016 Academic Editor: Yangmin Li Introduction gears.2,3 The relative sliding between the driving and driven tooth surfaces of conventional conjugated sur- The meshing of conventional gears is usually based on face meshing gears is the main factor which causes the the principle of conjugate surface meshing.1–3 The basic 4 transmission failure of wear, scuffling and plastic defor- kinematic relations proposed by Litvin and Fuentes mation, especially in worm gears.2,3 relate to the velocities of the contact point to the con- tact normal for a pair of gears that are in mesh. 5 6 Involute gears, parabolic gears, cycloidal gears and 1 7 School of Mechanical Engineering and Electronic Information, China circular arc gears, which are widely used in industry University of Geosciences, Wuhan, P.R. China applications, are designed and manufactured strictly 2Wuhan East Lake Innovation Base Company Limited, Wuhan, P.R. China according to this conventional principle of conjugated surface meshing. However, curvature interference and Corresponding author: undercut strongly limit the design of tooth profiles and Zhen Chen, School of Mechanical Engineering and Electronic Information, China University of Geosciences, No. 388 Lumo Road, Wuhan 430074, number of teeth, especially in conventional gear P.R. China. designs, for example, involute gears and cycloidal Email: [email protected] Creative Commons CC-BY: This article is distributed under the terms of the Creative Commons Attribution 3.0 License (http://www.creativecommons.org/licenses/by/3.0/) which permits any use, reproduction and distribution of the work without further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/ open-access-at-sage). 2 Advances in Mechanical Engineering The space curve meshing equations have been estab- lished by Chen et al.8,9 and Chen10 who thereby estab- lished the meshing theory of conjugated space curves. Then, Chen and colleagues11–13 developed the conju- gate curves theory for arbitrary contact directions. Utilising the space curve meshing equations, line gears have recently been extensively studied for microelectro- mechanical system (MEMS), including space curve meshing wheels (SCMWs)14–17 used in case of intersect- ing axes with an arbitrary intersection angle and space curve meshing skew gear mechanism (SCMSGM)18 Figure 1. The space curve meshing coordinate systems for used in case of skew axes with an arbitrary skew angle. parallel-axis transmission: (a) u = 180° and (b) u =0°. However, the driving and driven tines of these line gears can both be regarded as cantilever beams, which cannot absorb enough loading for conventional According to the space curve meshing theory, for a mechanical applications. If the loading is for conven- pair of conjugated space curves that are in mesh, the tional power transmission, transmission failure occurs relative velocity at the contact point and the principal in the form of elastic deformation or even a fracture of normal vector at the contact point must therefore sat- 9 the tines of line gears. Thus, the line gears introduced isfy the following space curve meshing equation above are mainly suitable for micromechanical systems (12) with a low power,10 and this restricts the applicability v b = 0 ð2Þ of space curve meshing theory. For the following calculations, a cylindrical helix By adopting the concave–convex meshing form of was chosen as the driving contact curve and the mesh- arc gears, which offers the advantage of a large syn- ! ing point is denoted as P. OP is the position vector thetic curvature radius, a geometry design method for ! r (t)ofP in S . O P is the position vector r (t)ofP in the design of a novel pure rolling circular arc helical 1 1 2 2 S . The equation of the driven contact curve in S is gear mechanism (CAHGM)19,20 with concave–convex 2 2 denoted as r (t), which can be solved by meshing is presented in this article for parallel transmis- 2 sion applications. Then, a formula for calculating the r2 = M21r1 ð3Þ contact ratio for CAHGM is given. After the analyses T of contact ratio, the parameter design for CAHGM is where r1 = ½ x1 y1 z1 1 and r2 = T presented. Furthermore, the experiments were per- ½ x2 y2 z2 1 . formed to study the kinematic performance of the fab- For a right-handed cylindrical helix as an example of ricated CAHGM prototypes to validate the theoretical a driving contact curve, the right-handed driving con- transmission model established for the CAHGM. tact curve in S1 is given by r1(t)=R1 cos ti1 + R1 sin tj1 + R1(p + t) cot bk1 ð4Þ Geometry design of CAHGM for parallel x = R cos t axes transmission 1 1 y = R sin t Space curve meshing coordinate transformation 1 1 matrix for parallel transmission z1 = R1(p + t) cot b There are two ways for achieving parallel transmission where R1 is the helix radius; b is the helix angle and t is when designing a pair of CAHGM, that is, external the variable parameter of the cylindrical helix, with gearing and internal gearing. Figure 1(a) and (b) shows t Àp. the coordinate system for external gearing and internal The unit principal normal vector of the driving con- gearing, respectively. tact curve can be represented by21 The coordinate transformation matrix M21 can be expressed by 2 3 cos f1 cos f2 + sin f1 sin f2 cos u sin f1 cos f2 À cos f1 sin f2 cos u 0 a cos f2 6 cos f sin f cos u À sin f cos f sin f sin f cos u + cos f cos f 0 a sin f cos u 7 M = 6 1 2 1 2 1 2 1 2 2 7 ð1Þ 21 4 00105 0001 Chen et al. 3 r(t) b = ð5Þ r(t) The relative velocity vector at the meshing point is then given by9 v(12) = v(1) 3 r(1)(t) À v(2) 3 r(2)(t) ð6Þ When v1 is given, the relationship between t and f1 can be calculated through solving equation (2) and the coordinate transformation matrix M21 for a transfor- mation from S1 to S2 can be obtained. Combining equa- tions (2), (5) and (6) yields the following equation f1 = p + t ð7Þ Figure 2. Illustration of two conjugated cylindrical helixes of an external gearing mechanism for parallel-axis transmission. Equation (7) indicates the one-to-one relationship between f1 and t. This means that the point corre- sponding to a certain value of t on the driving contact opposite of the helix angle of the driving helix. For curve will become the meshing point after the driving 9 internal gearing, the helix angles are identical. In gear is rotated by an angle of p + t. Theoretically, if Figure 2, two conjugated cylindrical helixes are shown there is no interference between the two gears, the value 9 for parallel transmission and an external gearing range of t may be without limit. Thus, the application mechanism. of space curve meshing theory has the advantage of the For parallel transmission, there are two possible absence of a meshing limit, which is responsible for the designs for the meshing between the two cylindrical undercut of conventional gears. helixes: a right-handed cylindrical helix for the driving Therefore, the rotation angle of the driving gear for curve and a left-handed cylindrical helix for the driven the rotation of a driving tooth from entering the mesh- curve; or a left-handed cylindrical helix for the driving ing to withdrawing from the meshing is Df1 = Dt.In curve and a right-handed cylindrical helix for the this study, the value range of t was adjusted to driven curve. Point contact meshing occurs in both Àp t Dt À p.9 According to Figure 1, the centre dis- cases, and the contact points form a straight line N1N2 tance a between the two axes can be calculated by in a fixed coordinate system.