Prediction of Machining Deformation for Split Equal-Base Circle Bevel Gear

Abstract

Given the deformation issues in machining segmented equal-base bevel gears, this paper investigates the variations of additional stress during the machining process, considering the gear blank material, residual internal stress, and gear blank design. A model for calculating internal additional stress and torque during gear machining has been developed. The calculation formula for the bending deformation of the gear blank has been derived using the torque–area method. By analyzing the time-varying stiffness of the blank, a calculation model for the bending deformation of the gear blank has been constructed, and the projection analysis of gear stock deformation has been completed. Based on the cumulative superposition effect of its deformation projection, a calculation model for the overall deformation of the segmented gear blank has been formulated. The deformation calculation model has been validated through finite element simulation, deformation calculation, actual machining, and measurement verification.