Simulation and optimization of computer numerical control-milling model for machining a spiral bevel gear with new tooth flank

Abstract

Distinguished with the traditional tooth flank of spiral bevel gears, an accurate spherical involute tooth profile is of obvious advantages for the design and manufacture. For obtaining the gear model with enough tooth flank accuracy, simulation and optimization methodologies of computer numerical control-milling model are proposed. Initially, it gives an identification of the spherical involute tooth flank based on an improved formation theory. A universal simulation machining of the universal multi-axis computer numerical control-milling center is proposed to obtain an initial model. Then, in order to get/for getting improved tooth flank accuracy of the initial gear model, it presents some optimization methods included in the applications which are (1) non-uniform rational B-spline reconstruction by the Skinning method and (2) an overall interpolation based on Energy method. Finally, some given numerical examples are utilized to verify the form error of tooth flank. In addition, a closed-loop experiment scheme is provided to verify the validity of proposed methods.