Optimal Modifications of Gear Tooth Surfaces

62 Management Summary In this paper a new method for the introduction of optimal modifications into gear tooth surfaces—based on the optimal corrections of the profile and diameter of the head cutter, and optimal variation of machine tool settings for pinion and gear finishing—is presented. The goal of these tooth modifications is the achievement of a more favorable load distribution and reduced transmission error. The method is applied to face milled and face hobbed hypoid gears. Corresponding computer programs are developed. By using these programs, the optimal head cutter geometry and the optimal machine tool settings for pinion and gear tooth processing are determined. The influence of tooth errors and misalignments of the mating members on load distribution and transmission error is investigated. The obtained results show that the influence of tooth errors and misalignments on gear performances is significantly reduced by the introduction of optimal tooth modifications.