AGMA-02FTM11-2002.pdf
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1、02FTM11 A Gear Design Optimization Procedure that Identifies Robust, Minimum Stress and Minimum Noise Gear Pair Designs by: D.R. Houser and J. Harianto, The Ohio State University TECHNICAL PAPER American Gear Manufacturers Association Copyright American Gear Manufacturers Association Provided by IHS
2、 under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:37:43 MDTNo reproduction or networking permitted without license from IHS -,-,- A Gear Design Optimization Procedure that Identifies Robust, Minimum Stress and Minimum Noise Gear Pair Designs
3、D.R. Houser and J. Harianto, The Ohio State University Thestatementsandopinionscontainedhereinarethoseoftheauthorandshouldnotbeconstruedasanofficialactionor opinion of the American Gear Manufacturers Association. Abstract Typicalgeardesignproceduresarebasedonaniterativeprocessthatusesratherbasicform
4、ulastopredictstresses. Modi- fications such as tiprelief andlead crowningare basedon experienceand thesemodifications areusually selectedafter the design has been developed. In the traditional approach, the selection of the optimal designs is really sub- -optimal, since there are always compromises
5、that are made between the many design performance evaluation variables. Thedesignprocedurethatisdescribedinthispaperstartswithmicro- -topographiesintheformofprofileandleadmodifi- cations that are appropriate for a given design and that are easyto manufacture. Wethen evaluatethe loaddistribution, ben
6、ding and contact stresses, transmission error, film thickness, flash temperature, etc., for a large number of designs (sometimesasmanyas1million)inanefforttofindthe“best”designforthepredeterminedtoothmicro- -topographies. Thekeytotheanalysisistherapidevaluationoftheloaddistribution. Auniquegraphical
7、lyorientedselectionprocedure is then used to determine designs that are good in many of the above mentioned design response variables. The best of these designs are then subjected to an evaluation of the effects of manufacturing errors on the performance evaluation variables(stresses,noiseexcitation
8、s,etc.). Designsthatareleastsensitivetomanufacturingerrorsarethendeemedmost robust and hence “best” for the given application. Copyright 2002 American Gear Manufacturers Association 1500 King Street, Suite 201 Alexandria, Virginia, 22314 October, 2002 ISBN: 1- -55589- -811- -4 Copyright American Gea
9、r Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:37:43 MDTNo reproduction or networking permitted without license from IHS -,-,- 1 A GEAR DESIGN OPTIMIZATION PROCEDURE THAT IDENTIFIES ROBUST, MINIMU
10、M STRESS AND MINIMUM NOISE GEAR PAIR DESIGNS Dr. Donald R. Houser and Jonny Harianto Department of Mechanical Engineering The Ohio State University 206 West 18th Avenue, Columbus, OH 43210 Phone: (614) 292-5860 Fax: (614) 292-3163 email: houser.4osu.edu INTRODUCTION The design of a gear pair is, ind
11、eed, a complicated process. Usually there are many measures of a good design including bending and contact stress balancing and minimization, minimizing scoring features such as flash temperature, and minimizing noise. Noise minimization is seldom considered in great detail at the initiation of a de
12、sign, but is often considered only when noise becomes a problem. In addition, the designer seeks to find designs that are insensitive to manufacturing and mounting errors. In order to achieve good designs the designer may vary a large number of geometry and manufacturing factors such as number of te
13、eth, pressure angle, helix angle, tooth height, hob shift, etc. Usually designers apply their past experiences to select design parameters, but due to the tedium of the process may not consider very many alternative designs. Also, the tooth surface micro- geometry that is defined by the tooth topogr
14、aphy is rarely considered at the beginning of a design, but may be considered after the main geometric parameters are chosen. This paper presents an optimization methodology that allows the manipulation of a large number of design parameters and allows selecting designs that are superb in many of th
15、e measures of goodness that the designer chooses to use. Tooth micro-design and design for minimum noise are considered throughout the design process and finally, the procedure allows one to assess the sensitivity of the design to manufacturing and assembly deviations. DESIGN OPTIMIZATION Design opt
16、imization has, over the past couple of decades, literally become an engineering specialty. Yet most demonstrations of optimization techniques vary few design variables and use relatively simple objective functions for the optimization of the designs. We will first discuss design optimizations issues
17、 encountered in gear design and then present a unique gear design optimization approach. Macro vs. Micro Gear Design By macro design we mean the varying of design parameters such as numbers of teeth, pressure angle, helix angle, etc. Changing these parameters can have a large effect on evaluation pa
18、rameters such as root stress or contact stress and allows the application of evaluation equations such as those used by AGMA 1 or that appear in design textbooks. Micro-design is the establishment of the specification of the shape of the gear tooths active profile. This procedure includes the applic
19、ation of lead crowning and lead modifications that are often necessary for compensating for misalignment and mounting inaccuracies and profile modifications that are used to reduce contact along the tooth tips and roots and for noise reduction. Micro design is usually applied after one has selected
20、the macro-design parameters. Although the shapes used in micro-design are unlimited, manufacturing considerations usually limit the complexity of the shapes that are practical. Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001
21、, User=Wing, Bernie Not for Resale, 04/18/2007 11:37:43 MDTNo reproduction or networking permitted without license from IHS -,-,- 2 Optimization Background Most gear designers 2-5 who have used design optimization have applied their methodology using conventional gear stress formulas in a macro-desi
22、gn approach. The approaches used usually have taken into consideration only one or two parameters and have rarely considered such conventional design approaches as the balancing of the strength and durability lives or the balancing of bending strength between the pinion and gear. Each of these crite
23、ria is best solved using cutter profile shift in order to adjust tooth thickness of the gear and pinion. The optimization approach applied by these authors requires the selection of an objective function that is usually minimized using some type of steepest ascent method. We have observed several di
24、fficulties with conventional gear design optimization techniques: 1. The number of design variables in even the simplest gear design is of the nature of from 6-10. With this number of variables we find that there are many combinations of design variables that provide near optimum solutions. These mu
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