Impacts of Misalignments on Mesh Behaviors of Face-Hobbed Hypoid Gear Considering System Deformation

Considering the system deformation, a procedure to predict the mesh behaviors for face-hobbed hypoid gear pair in car rear axle was proposed based on the tooth surface model and the finite element analysis (FEA) tooth contact model. The mathematical model of face-hobbed hypoid gear was derived based on the manufacturing process. The systematic model of the whole rear axle was developed in Masta, and the misalignments caused by system deformation of the hypoid gear pair was calculated. The impacts of the comprehensive misalignments and independent misalignments on mesh behaviors of hypoid gear were studied, respectively. Results show that the comprehensive misalignments under the rated load level have less influence on the contact characteristics. However, for the parametric studies of independent misalignment, the offset misalignment, and the gear axial misalignment have obvious influences on the contact pattern and transmission error. The peak-to-peak value for angular transmission error with the offset misalignment decreases significantly, when misalignment change from negative to positive. While that with the gear axial misalignment increases progressively. For shaft angle misalignment has an obvious impact on the location of the contact area and it causes a little increase of the peak-to-peak value for transmission error. Relatively, the pinion axial misalignment has diminutive impacts on the contact pattern and transmission error.