Research on meshing mechanism and design method of small offset and large offset hypoid gear transmission

For small crossed shaft angle situation, hypoid gear transmission has the advantage of more compact structure，higher carrying capacity and adaptability for wider shaft angle range compared to the current involute gear transmission. It can be widely used in the spatial transmission area of speedboat, vehicles and aviation. However, the sharp decrease of shaft angle and increase of offset lead to an extreme change of the geometry parameters. The evolution of the tooth profile and the meshing theory are not yet clear due to the extreme change of the geometry parameters. And it is much difficult to manufacture the hypoid gear with large cone distance. The conventional geometry design theory based on the orthogonal installation can not work for the design situation with small shaft angle and high offset. Based on the gear meshing theory, contact analysis method and vibration theory, the research on the tooth profile evolution, pitch cone design theory, manufacturing, mesh characteristics and dynamic characteristics will be performed for the hypoid gear pair with small shaft angle and high offset. The pitch cone design model will be developed and the tooth profile evolution and meshing theory for hypoid gear with extreme change of the geometry parameters will be revealed. The manufacturing model based on loaded tooth contact analysis and dynamic model will be developed. The optimization method for the manufacturing parameters of the hypoid gear with large cone distance based on the pre-control of the mesh behaviors will be proposed. Then breaking through the limit of current geometry design method, the geometry design method for the hypoid gear with small shaft angle and high offset will be proposed. The corresponding professional design software will be developed. Finally, the prototype will be manufactured, whose shaft angle is 20 degree, offset is larger than the gear radius and transmission ratio is 1~1.5. Experiments will be performed to validate the theoretical results. This project will lay a theoretical foundation for the industrialization of this type of transmission.