Modelling and undercutting analysis of beveloid gears

Abstract

Different from conventional conical gear geometries, beveloid gears are gears types, which can work both on parallel and crossed axes. Due to this specialty, their wide field of use has made mathematical models and computer aided analysis extremely important in terms of their optimization and design. Undercutting is an other important factor, which effects the load distribution and root strength in a negative way. Considering these two subjects together, it has thought that, modelling of beveloid gears which has optimization on prevention of undercutting, can bring an innovation in a wide range. Although there are methods suggested to prevent undercutting, a whole study which includes the implementation of the methods on the beveloid gears and stress analysis of the developed models does not exist. In the scope of this work, mathematical modelling which is especially convenient for 3 dimensional modelling with fused deposition modelling method (FDM) has been focused on, undercutting phenomena has been studied and modifications which can help to prevent undercutting has been specified in the equations. Finally, under the conditions which undercutting occurs, stress distribution on the root regions has been generated by finite element method (FEM) and to prevent the undercutting formations, positive profile shifting and production with asymmetrical rack cutter methods has been used. In the result of the stress analysis, it has been seen that, maximum stress values on the root regions has been reduced. By the help of these two methods, it can be possible to increase the strength on the root regions of the beveloid gear models