Process and Tool Design Optimization for Hypoid Gears with the Help of the Manufacturing Simulation BevelCut
In this paper, the mode of operation as well as the current scope of the manufacturing simulation BevelCut was presented. The cutting characteristics for an exemplary design were evaluated for both pinion and ring gear manufactured using face hobbing rolling and plunging. A relationship between the simulation results and cutting phenomena was established. Based on this relationship, corrective measures were deduced. The simulation results show a successful optimization of the tool and process parameters for the gear design. Thus, for the first time, a simulation-based tool and process optimization were conducted for face-hobbing processes.
Profile Shift
The objective of this report is to determine the origin of the phrase “profile shift.” Several technical books, technical papers, and industrial standards were reviewed for nomenclature associated with profile shift. The phrase “profile shift” translates directly to the German term “Profilverschiebung,” which originated in the last quarter of the 19th century. At first, profile shift was used to avoid undercutting pinions with small numbers of teeth. Later, it was recognized that profile shift improved the load capacity of the gear mesh and extended the service life of manufacturing tools.
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