Design, manufacture, stress analysis, and experimental tests of low-noise high endurance spiral bevel gears

The contents of the paper cover the design, manufacturing, stress analysis, and results of experimental tests of prototypes of spiral bevel gears with low levels of noise and vibration and increased endurance. The main goals are the improvement of the bearing contact, the achievement of a predesigned parabolic function of transmission errors, reduction of the magnitude of transmission errors as the precondition of reduction of noise and vibration, and avoidance of areas of severe contact stresses for the increase of the endurance of the gear drives. The goals are achieved by application of local synthesis algorithm, tooth contact analysis, and stress analysis by application of finite element method. The proposed ideas have been proven by the manufacturing and test of prototypes of spiral bevel gear drives. An example of design and optimization of a spiral bevel gear drive for the illustration of the developed theory is represented.