.Advanced Theories of Hypoid Gears PDF

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STUDIES IN APPLIED MECHANICS 36
Advanced Theories
of
Hypoid G e a r s
X.C.Wang
Department of Mechanical Engineering
Xian Jiaotong University
Xian, P.R.China
S.K.Ghosh
GKN International College of Engineering
Sieg burg, Germany
ELSEVIER
Amsterdam - London - New York-Tokyo 1994
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<iei
Foreword
The importance of gears as the principal mechanisms for transmitting motion in

many types of application is well-known. However, the same cannot be said of the
theories of gear engagement, nor of the gaps which have been left by previous
research into this subject.
Professor Wang and Professor Ghosh have combined, in a striking example of

international collaboration, to produce this excellent book of advanced theories,
which can be used for all types of gears.
As a major contribution to the subject of gear engagement theory, the book should
be prescribed reading in academic and research institutions, as well as for engineers
involved with the design and manufacturing of gears in many sectors of industry.
January 1994 Trevor C. Bonner

G K N p l c , London
v
Preface
Gears are the most widely used transmission elements in machines and instruments.
With the development of technology, gears are now required to work at even higher
speeds, carry heavier d u t y , and transmit movement more accurately than even be-
fore. At the same t i m e , we want gears that can be manufactured economically and
with better quality. In order to achieve these purposes, a further investigation into
the theories of engagement is necessary.
Gears can transmit rotational movement between parallel a x e s , intersecting axes and
crossed axes. They are divided into many g r o u p s , e. g. cylindrical g e a r s , bevel
gears, worm gears and hypoid gears. Previously, most of the research work on the
theories of engagement were carried out separately on different g r o u p s , and many
were based on individual types of profiles. The results and conclusions obtained in
one situation can hardly be applied to others. Since t h e n , more and more types of
gears and profiles have been developed and used in practice. To carry out research
work in this way seems to be obsolete. The authors believe that some universal theo-
ries should be developed, which can not only be used for all the types of g e a r s , but
will also be utilized in other fields such as sculptered surfaces. As we k n o w , the
transmission of rotational movement between crossed axes is the most complicated
and universal situation. Without being confined to a certain type of profile, the theo-
ries and algorithms obtained can be applied to all kinds of gears. A typical example is
a pair of hypoid g e a r s , which has the most characteristics of all gearings.
As it is well k n o w n , the meshing of hypoid gear drives and spiral bevel gears with
vn
νπι
Gleason gearing is approximate. This implies that the contact is only a point if the
load is equal to zero» and the angular velocity ratio changes in the process of mesh-
ing. Many efforts have been made todate to reduce the kinematical errors and im-
prove the contact situations of this type of gears. At present the contact performance
is generally investigated by means of Tooth Contact Analysis ( T C A ) methods1-1'211.
However, these are time consuming. In addition, they generate a large amount of
numerical and graphical information which then requires further analysis in terms of
parameters or the subjective judgement of a user. Prof. F. L. Litvin has attempted to
control directly the geodetic curvature of the contact point path on the gear flank [3] .
Unfortunately, he was unsuccessful with other parameters. Furthermore, his un-
suitable supposition that all the third order derivatives of tooth surfaces are equal to
zero, made his method unreliable. In recent years, he has developed a method of ma-
chining conjugate spiral bevel gears [4,5] . However, it can neither be used yet for ma-
chining hypoid gears, nor can it guarantee comprehensive contact situations.
Although the theoretical surfaces can be obtained, it is well known that high speed
and heavy duty gears are generally modified and crowned to obtain a better contact
performance and to reduce the vibration caused by the change of contact rigidity in
the meshing process. The book will describe, amongst other several derivations, a
method developed by the authors to control strictly the mismatch amounts for these
kinds of gears so that the mismatch can serve the purpose of modification and crown-
ing C9,11] . In order to do this, several steps are needed: i) directly controlling as many
contact parameters as possible according to anticipated contact situations Cl2] ; ii) for
those parameters which cannot be controlled directly, an analysis in terms of param-
eters being applied instead119,11,15]; and, iii) based on the analysis, an optimal synthe-
sis being carried out for controlling the contact parameters which cannot be con-
trolled directly Cl4] . Using the proposed method developed by the authors, the posi-
tion of the centre point of tooth bearing and the second order contact situations can
be predicted and kept unchanged, while the optimal synthesis can automatically be
completed without any intervention by the user. In the process of developing the al-
gorithms, the authors have introduced some mathematical methods which are be-
lieved to be innovative with regard to the theories of engagement known so far. The
theoretical treatment is presented throughout the book, supported by numerical ex-
amples and experiments. With the computer programs listed at the end of the vol-
ume , any of the proposed method can be easily utilized in practice.
IX
The book has four characteristics· i) the investigations are concentrated on mis-
matched tooth surfaces; ii) all the problems are dealt with from differential geometry
point of view; iii) most theories and algorithms are universal in applications; and iv)
the algorithms are easy to follow and to be utilized in real situations.
This book is divided into seven chapters. The theories and algorithms developed in
Chapters 1 , 2 , 4 and 7 are universal. A method to analyse the contact situations of
combined mismatched tooth surfaces up to the third order contact is introduced in
Chapter 1. The algorithms for obtaining the geometric parameters of tooth surfaces
which are required in the analysis process are presented in Chapter 2. From the cal-
culation point of view, tooth parameters should be obtained at first. Since it might
be difficult for readers to accept too many new concepts at the very beginning, the
first two chapters are reorganized. A method of presetting second order contact pa-
rameters is given in Chapter 4. By means of this method, the second order contact
situations can be predetermined and kept unchanged in subsequent optimal synthesis
process. Thus local synthesis is on longer necessary. A mathematical model of the
sensitivity of contact situations with respect to the misalignments is derived in Chap-
ter 7. Some latent applications are also discussed. The vertical ( V ) and horizontal
( H ) check process is dealt with from differential geometry point of view in Chapter
3 , to obtain the rates of change of the contact situations in parameter forms. Chapter
5 introduces the determination of machine setting parameters. The algorithms are
specially designed for machining spiral bevel and hypoid gears with Gleason gearing.
It is much simpler than those developed by Gleason Works. Moreover, more setting
parameters are offered, which can be freely chosen. A method for optimal synthesis
of the third order contact situations is presented in Chapter 6. The whole calcula-
tional process is described in this chapter. Some numerical examples are given to il-
lustrate the way of presetting the second order contact parameters correctly. Finally
Appendices 1 — 4 present listing of computer programmes with an example.
This book is intended for the postgraduate s t u d e n t s , lecturers, professor, or re-

search staff in mechanical/manufacturingengineering, mathematics and R &· D of de-
partments of esearch institutes and universities and for engineers working in the gear
manufacturing sector of industry.
Xian, P R China, Siegburg, Germany, June 1993

X . C . Wang
S.K. Ghosh
Acknowledgments
Ife authors would like to thanfi their colleagues at Xian Jiaotong and Staffordshire
Universities. The second author is particuCarCy gratefuC to Mr. %§ith (Burfe, Managing
(Director of QcK3^!A?(Ces Limited (Salisbury 'Division) in Birmingham, England for hi
comments and for providing us with the photographs on the cover. cThese Qütyt
diff erenticds/gears are part ofcities which go into Jaguar, Vauxhaiifrontera, Land%gver
etc. vehicles.
Our thanks are also due to (Dr. (Bos van der 9ioe(^ and Ms. (Mary McSidam of the
'Engineering and technology Section of Eiserner Science ûbtishers for their co-operation
and help.
Professor S K Ghosh
GKN International College of Engineering
Siegburg, Germany
X
1
Analysis of Combined Mismatched

Tooth Surfaces up to and Including
Third Order Contact
1.1 INTRODUCTION
The meshing between a pair of tooth surfaces is line contact if they contact each oth-
er along a line in the whole meshing process when the load is equal to zero. The
meshing is called point contact if the surface contac is a point when the load is zero.
Under a load, the instantaneous contact spreads to an elliptical s p o t , which moves a-
long the tooth surface, covering a localized tooth surface and forming an envelope
around it on the tooth surface. This envelope is called a tooth bearing. If the trans-
mission ratio of a pair of point-contact tooth surfaces changes during the meshing
process, the meshing is called combined mismatched. Line-contact surfaces are very
sensitive to machining errors and misalignments. Many theoretical line-contact sur-
faces are modified to obtain a local contact. On the other h a n d , for some kinds of
gears such as Gleason type hypoid g e a r s , the theoretical line-contact tooth surfaces
are difficult to obtain. For these gears, it is only mismatched tooth surfaces that can
be manufactured using available equipment and are widely used in practice. Since
2 ADVANCED THEORIES OF HYPOID GEARS
mismatched gears have many applications, better understanding of the contact situa-
tion between the surfaces , and a better method of controlling them in advance is re-
quired. In order to achieve this, an effective method for analysing the contact situa-
tion directly in terms of parameters has to be developed at first1-9-1. In this manner an
objective function for the evaluation of the contact quality can be easily composed and
no further analysis is required.
An analytical method, without any unreasonable assumption, is presented in this

chapter for the analysis of contact situation of a pair of combined mismatched tooth
surfaces up to and including third order contact. Since all formulae are presented in
explicit form, a rapid response from a computer can be expected. This method is
subsequently verified by the simulation performed by high-accuracy Tooth Contact
Analysis (TCA) program.
e3«,>
a"
Fig. 1.1 An illustration of the contact of mismatched surfaces
1. 2 ESTABLISHMENT OF MOVING FRAMES
The moving frame theory is well known in differential geometry. However, in that
THIRD-ORDER CONTACT ANALYSIS 3
situation it is only one surface rigidly connected to the coordinate system that is con-
sidered. Here we shall develop the theory into the situation of two surfaces in contact
and rotating about individual axes. Let us suppose that surfaces Σ α > and Σ ( 2 > are
known tooth surfaces which can rotate about their own axes. Their rotation angles
are denoted by φ{Ώ and φ(2>, respectively. The unit vectors of their axes are denoted by
a (1) and a<2>. The parameters of 2 ( 1 > are ux and u29 and the parametric curves coincide
with the lines of curvature of Σ ( 1 ) · Similarly, vx and v2 are the parameters of Σ ( 2 ) >
and the parametric curves coincide with the lines of curvature of Σ ( 2 ) . Let r ( 1 ) denote
the position vector of a certain point on Σ α ) in the moving coordinate system rigidly
dra) dra)
connected to gear 1. The unit tangents of -z— and —— are denoted by el and e2 with
a U\ a U2
e3 being the outward unit normal at this point. It is assumed that e19 e29 and e3 com-
pose a right-handed system (otherwise the direction of one of the parametric curves
will be reversed). T h u s , a moving frame {r ( 1 ) ; el9 e29 e3} is established for each
point on Σ α > . This is a two-parameter moving frame, the parameters being ul and
w2. Similarly, a moving frame system {r<2>; el9 e 2 , e3} can also be established for
Σ ( 2 > . The difference is that the parameters are i ^ a n d i ^ , and e 3 is an inward unit nor-
mal.
In fixed coordinates, Ra) denotes the position vector from a poit fixed on the axis of
Σ ( 1 > to a certain point on Σ ( 1 ) and R(z) denotes the position vector from a point fixed
dRa) 3r(1)
on the axis of Σ ( 2 ) to a certain point on Σ ( 2 ) ( F i g . 1 . 1 ) . Since — = —— and
d Ra) 3r(1) —
- - - .
— = — , a 3-parameter moving frame {Ra); el9 e29 ez) is established for each
d U2 a u2
point on Σ ( 1 ) in the fixed coordinate system, the parameters being u19 u2 and <pa).
Similarly, a 3-parameter moving frame {i? <2) ; ε19 ε 2 , ε3} can also be established for
each point on Σ ( 2 ) in fixed coordinates, the parameters b e i n g v l 9 v2and<p<2). Thus for
each surface both 2- and 3-parameter continuous sets of Frenet frames are estab-
lished, and their parametric curves coincide with the lines of curvature.
1. 3 D I F F E R E N T I A L FORM O F MOVING F R A M E S
The moving frame {r ( 1 ) ; eX9 e29 ez) has thd differential form in the moving coordi-
nates rigidly connected to gear 1 as follows :
d r(1> =<o1e1 + ω2β2
d ex =<o\e2 + ω\β3
(1.1)
d e2 = — (o\ex + w\e3
d e3 = ω\βχ
where
~ 3 _ Z,(l) 7-T1 7-T3 _ 1(1) 7-T2 7-T2 _ Λ (1) ~ 1 I Λ (1) ~ 2 (1.2)
Cüi — * i C ü > C Ü 2 — *2 Cü > Cüi — /°i CO v Pi CO
in which k[iy and £2° are the principal curvatures of Σ α > along ux and u2 parametric
curves, and p[iy and ρ2Ώ denote the geodetic curvatures of ux and u2 parametric curves,
respectively. Similarly,
d r<2) = Ωι~εχ + Ω2ε2
ά ~εχ = Ω\~ε2 + Ω\ε3

(1.3)
ά ε2 = — Ω\εχ + Ω\εζ
d ε 3 = — Ω\εχ — Ω\ε2 J
where
Ω\ = k™ Ω\ Ω32 = k™ ß 2 , ΐΐ\ = ρ™ Ω1 + ρ™ Ω2 (1.4)
in which k[2) and k(22> are the principal curvatures of Σ α > along vx and v2 parametric
curves, and px2) and p22) denote the geodetic curvatures of vx and v2 parametric curves,
respectively.
As both gears rotate about their own axes together with the moving coordinates con-
nected to them, the differential forms of the 3-parameter moving frames take the
forms in the fixed coordinate system as follows:
d# ( 1 ) = d r ( 1 ) + α α ) X R™aqP>
dex =dex + α α > X ex d^ x)

(1.5)
de2 = de2 + ä(1> X ~e2a<fl·"
de3 = de3 + α α > X β3ά^

d#<2> = d r<2) + ä (2) X Ri2) άφ{2)
d ^ = d ^ + ä<2) X ε,άφ^
<2) (1.6)
άε2 =άε2 + ä X e 2 d^ ( 2 )
d i 3 = d e 3 + ä(2> X e 3 dp < 2 )
1. 4 R E S T R I C T I N G CONDITIONS FOR C O N T A C T
From the process of establishing the moving frames we know that each moving frame
in the fixed coordinates depends on a set of three parameters, so that the relationship
between the moving frames belonging to the different surfaces is to be determined by
all the six parameters. This represents a general situation without considering
whether the surfaces are in contact with each other. Hereafter, the only situation
being considered is that both surfaces are in contact with each other and both moving
frames are at the contact point.
From Fig. 1. 1 it is easily seen that
fl<l> = fl<2> + L (1.7)
To make the surfaces in contact, the normals must coincide with each other. Since e3
is an outward unit normal and ε3 an inward o n e , we have
£3 — £3 (1.8)
When both axes are fixed o n e s , L is a constant vestor. Since these conditions are al-
ways true in the whole meshing process, we have
d# ( 1 > = d # ( 2 ) (1.9)
de3 = d e 3 (1.10)
These are the restricting conditions to ensure the surfaces in a continuous contact sit-
uation, which contains five numerical equations, so both moving frames are deter-
mined by only one parameter.
1. 5 SECOND ORDER CONTACT ANALYSIS
As we know, the mathematical expression of a surface can be developed into a Tay-

lor series in a local sense. If x and y coordinate axes are individually along the princi-
pal directions of the surface at the contact point and z along the unit normal , the ex-
pression can be simply writen in the form
z = -k^x1 + -k2yz + *
where * denotes the higher order residual items. Thus the principal directions and
curvatures of a surface at a point are known as the second order geometric parame-
ters at the point, and the contact situations determined by the parameters up to the
second order are called the second-order contact parameters.
Suppose the surfaces originally contact with each other at point M , and at this mo-
ment the position vectors Ra) and Riz) as well as the rotation angles <pa) and φ{2) are
known. Denoting the directed angle from ex to εΣ by ψ , then
εχ = cos ψ ex + sin ψ e2 )
e2 = cos ψ e2 — sin ψ ex J
FromEqs . ( 1 . 9 ) · ( 1 . 5 ) , ( 1 . 6 ) , ( 1 . 1 ) and ( 1 . 2 ) we obtain
ω1 *! + S 2~e2+ äa) X Ra) dp(1> = Ω1 ex + Ω2 e2 + ä<2) X £ < 2 ) dp<2) (1.12)
From the scalar product of both sides of the equation and e3, we get
d(p<2> Ga\Ra\e3)
=
d ^ - ^ - I (1.13)
a r
(a< 2 >,*< 2 \* 3 )
This is the instantaneous transmission ratio. Substituting Eqs. ( 1 . 5 ) , ( 1 . 6 ) » ( 1 . 1 )

and (1. 3) into Eq. ( 1 . 1 0 ) leads to
- 3» ex - Z\~e2+ äa) X *3 α Υ η = - Ω\ ^ - Ω\ ϊ2 + ä<2> X *3 d^ 2)

άφα)
It is supposed that —τ— = 1. From the scalar product of both sides of Eq. ( 1 . 12)
and the above one with el9 e 2 , respectively, we have
_Ωι
& + (α«>,*«\0 ^ = - ^ cos I + ^ sin φ + (*<»,*<» ,e x )
_ß 2
JU + ( 5 < 2 \ * < 2 \ έ 2 ) J g = - - ^1 sin 0 + ^ >1 cos φ + (^>,^>,e2)
d^'> d^ d^
^ d f ^ + "<2>'έ* | S = - * i ° d f * c o s * ~ « l > d ^ s i n * + 5<" ·

■ *?> df^ - "<2> '~ε>$ =**" df* s i n * - «° df*cos * ~ 5<1>' *
This set of linear equations can be reduced to
0+ sin 0 +
*KSF c o s SF <ä (l \* a \o] - *ίι> ά c o s *
* ? > [ " d ^ sin ^ + dd<p<^ cos ^ + ο α \* α \έ 2 )] + *ί1} 5 ^ sin ^

^2°
<2 τττΓ)
Ä7^0 cos 0 — α α > · ex
dp
*L<2)/~<2)
2 U , κp(2) , ez 2\; ",P (1) _
α-(2) . pε ^ r
ι^ι>
T h u s the projections of the moving velocity of the contact point along Σ α > on ex and
e2 can be obtained as follows:
bx (k[2) - ^ > ) sin ψ

b2 (k™ - £< η ) cos ψ
(1.14)
dp (1) A
(£<2) - k[l)) cos ψ bx

n
dk[ - ki2)) sin 0 62
d^ (1) (1.15)
where
Ck{2) - k[iy) cos ψ Ck{z) ~ k^) sin ψ
Δ = (1.16)
(k[l) - ki2)) sin ψ (*?> - *?>) cos ψ
bl = [£<2>(^<2>,#<2>,0 + 5<2> · e,] ^ y - kl»ta™9R™9iO - αα> · l2
(1.17)
£2 = [*<2>(α<2\*<2\έ2) - 5<2> . i j ^ - k™&»9R™9iJ + ä(1> · έχ
(1.18)
The projections of the moving velocity of the contact point along Σ ( 2 > on ex and e2 will
be
Ω1 1
= ω cos 0 + άφ™
dft W Wsin 0 + ( " α) '* α) ' έι) - ^ <2> ^ <2> î> gö> (ΐ·ΐ9)
Ω2 51
,a> " d ^ Sin * + W' C°S * + G(l) Äa>
* ··^ ~ ( 5 < , > · * 0 ^ ^ dß
(1.20)
Fig. 1. 2 Moving
directions of the
contact points
along surfaces
Thus the directed angles from the first principal direction of the surface to that of
CPP on the surface (illustrated in Fig. 1. 2) will be
If the angle from the longitudinal direction of the gear tooth surface to ε1 is 7 (see
Fig. 1 . 3 ) , the angle from the profile direction to that of CPP will be
o = 0<*> + η - (1.22)
Fig. 1. 3 Direction of
CPP on gear flank
dRa) de
Substituting the parameter values obtained into Eq. (1. 5) , -j-07 and , Λ can be de-
termined. Then, by differentiating both sides of Eq. (1. 13) and takingdR a ) = dRi2y
into account, the relative angular acceleration of gear 2 with respect to gear 1 will be
-^(21)
, . „ dtf<
2)
dy _ (1.23)
5<,i>
whe = ä^ 5<,> -- <u
αν (1.24)
denotes the relative angular velocity between the gears, and

-(21) __ Q f -<2) y DC 5 ( 1 ) X R<
V (1.25)
d^°
ω'
the relative velocity between the tooth srefaces at the contact point. Since -p^y and
O
i,jy denote the projections of the moving velocity of the contact point along both
surfaces on the principal directions ♦ the derivatives of the arc length of CPP on both
surfaces with respect to <p(1) can be written as
ds (1) ω2 \ 2 d5<2> Ω1 \i Ω2 \2
α)
VUî Md^ 1 a) iy a) (1.26)
άφ id**1*/
' ' d
,a<ffl /
Taking —r— = 1 into account, these derivatives can be considered as the moving
speeds of the contact point on the surfaces.
Fig. 1. 4 The principal directions

of the difference surface
The second order kinematic characteristics of the mismatched tooth surfaces have
been analysed so far. The contact spot on the surface will be analysed below. In Fig.
1. 4 t is an arbitrary vector on the tangent plane at the contact point, and A is the di-
rected angle from ex to £. The relative curvature between the surfaces along t can be
expressed by
£-(21) = *«> c o s 2 ( A _ φ) + *«> sin2(A - 0 ) - ä^cos 2 A - jfe^sin2 A (1. 27)
Suppose there exists an imaginary surface Σ ( 2 1 > which contacts both Σ ( 1 > and Σ ( 2 ) at
M, and along any tangent direction t , the normal curvature of Σ ( 2 1 ) equals to kjn).
This imaginary surface is called difference surface at M. The principal directions of

d^(21>
Σ ( 2 1 > can be determined by setting ,', = 0. T h u s the directed angle from ex to one
of the principal directions of the difference surface t1 can be obtained as follows :
id) _ I t -i - Ri2) sin 2ψ (1.28)

8
~ 2 Ra)
- # ( 2 ) cos 2ψ
where
Ra> = tta> _ £)/2, R«> = Cki2> - ^2>)/2 (1.29)
The angle from εχ to ii is
Λ<2> = λ<ι> - ^ (1.30)
As we k n o w , the principal directions of the instantaneous contact spot coincide with

those of the difference surface, and thus the inclined angle of the contact spot (see
Fig. 1.5) will be
«=f-A<2> (1.31)
Fig. 1. 5 An illustration of
the instantaneous contact
spot on gear flank
Both the principal relative curvatures can be expressed as

jfc«i> = £<2>cos2A<2> + £<2)sin2A<2> - ^$1)cos2A<1) - ^<1>sin2A<1) 1
[ (1.32)
jfe«i> = £<2>sin2A<2> + £<2)cos2A<2) - yfe^sin 2 ^ - i ^ c o s U ™ J
In practice, when a gear pair is under running test with marking compound on the
surfaces and the load is fairly light so that the elastic deformation of the teeth can be
neglected, the area where the distance between the surfaces is less then the thick-
ness of the marking compound δ can be regarded as the contact spot. Neglecting the
higher order parameters of the difference surface, the instantaneous contact spot can
be taken as an ellipse and the lengths of its minor and major axes (see Fig. 1.5) can
be found as follows:
ll
~ V£<21)' ' 2 = A rk> (1.33)
1. 6 T H I R D ORDER C O N T A C T ANALYSIS
Now let us consider the Taylor expansion of a surface at a certain point again. If the
expression is up to the third order, and x and y axes are along the principal direc-
tions, it will take the form
^1 2 l ^2 2 l ^1»1 3 I ^1.2 2 ι ^2,1 9 1 ^2,2 3 1
z = —xz + -y2 + -jhx* + -y*2y + ~Y*y + -j^y + *
where kitj is the partial derivative of k{ with respect to the arc length of the lines of
curvature, * the higher order residual items. T h u s the curvature derivatives of a
surface are called the third order geometric parameters of the surface, and the con-
tact situations determined by the parameters up to the third order are known as the
third order contact parameters. Here we will consider these contact parameters. As
we k n o w , the curvatures, k}iy = kjiyCu19u2)9 of Σ α > are functions defined in a do-
main on u1u2 plane. Since ω1 = ^Εα)άηλ and ω2 = v C a ) d w 2 » the Jacobian | J | =
(1)
G does not equal 0, thus the derivative of kfl) can be written as
dk}» =ki}}% (*,; = 1,2) (1.34)
Similarly,
d # 2 ) = k% & (i, j = 1 , 2 ) ( 1 . 35)
Substituting the values of ~rij) and Τ~7Ϊ) obtained from Eqs. ( 1 . 14) and ( 1 . 15) into
a n d
Eqs. ( 1 . 2) and ( 1 . 4 ) , the values of ~r~ä) T~ö> c a n be determined. Hence from
Eqs. ( 1 . 1 ) , ( 1 . 3 ) , ( 1 . 5) and ( 1 . 6) the values of the derivatives of ^ι, e2» ei> and e2
can be calculated.
dRa) d.R<2) de de
From differentiating both equations , (1) = , (1) and -p<fy = -j—<fy with respect to <pa)
we get
άωι - άω2 - ω1 aex ω2 de2 - ( 1 ) d # (1)

(1) 2 ^1 + a ) 2 e22 + J^/l) α) + α
fAsriW
(dp ) * ^ ( d p ) ^ d ^ d ^ ^ άφ(l) άφ
n J^l>n + J.0α> J ro (l) ^ X άφα)
άΩ1 - , d ß 2 - , ß 1 de\ . Ω2 άε2

( 1 ) 2 £ ll + £
(d9 ) (dp (1> ) 2 22 +[ d?>
(ArriW J ro (l) d? ( 1 ) '+ d ^ n d ^ >
a> Λ,Λ\)
d # ( (1>
d/? 1>
d©<2) - - d2©<2)
Qi Q Q
^ r _i_ -<2) v p(2) r
α>(1> d^(1> ^ (d^n)
} ω1 d d
dg d 2 2
' dkll) ^ .■ Kl)
im d S^l
\| ;~ "i
^ «il /f ^^2
^ 1
' ^
^ , Z.<1) d*>
d
^ | -
d?> > dd^^ n ^
a) x
(dy> a) ) 2 / x
d ^ n άφα) \ άφα) d? ( 1 ) ^ 2
(d?a))2/*2
d^2 , -M\ de
d ^ > d ^n>n +
' "(1> x d ? a )
/d*<2> ff „ d^ y ü\ de", ( d*<
2)
Ö2 dÖ 2 i
I d^(1) d ^ u "*" x (d^ ( 1 ) ) 2 / * d ^ a ) άφα) \ άφ α)
άφα) ^ 2
(dp ( 1 ) ) 2 / 2
. A^. + 5a)Xi?Ld^ (I) - d^2>

n ( 1 ) (1) a> 3
d^ ^ ' dp df ' (d^n)2
From the scalar product of both equations and ε19 e 2 , respectively, 4 linear equations
can be obtained as follows :
,1 dS1 S2 _ω|_| . y/ dS2 , 5 1 ω2 | , | - ( 1 ) d ^ - \

cos
M (d^ a> ) 2 ά^ άφαη ~*~sin φ
\ (d9 ) "^ d^> d ^ r Γ ' d ^ , £ l |
a) 2
_ dß^ _ _ß^_ J3L i5(,> ^ - | d ^ -(2) ^(2) έ dV2>

~ (d^ (1) ) 2 d(ffiy d^ n ^ \ 'dâ) · V d ^ ^ K ' ' lJ
(d^n)2
A
. ,| ~~JJl 2 ft)f
ωω' ,.,2 1 ,| d ^ . a»1
ω ft)j
ft)2 ι / - ( 1 ) dfl (1)
sin C0S
Art»r> AaP>\
fA«tv\* ~ cV
r\ (άφΰψ d ? a "^ *Ί (d^ ( 1 ) ) 2 d^ n
d^/ Γ Ό Υ 0 9^2
άΩ2
^"^ i
Ωι
""
Ω\
"*i _i_
d#(1)
„(2) ^*v
- \~rd ^
p i / (2) p ( 2 ) p \
d 2 y>r < 2 )
~
(1) 2 (1) (1) n 2 (1) U
(dp ) d¥> d^ ^ Γ '<¥ M^ ^ ' z)
' (άςρα))2
(dki»_ _ω dft)1 ω2 ω{ ^
— cos 0 Ξ L id) "w £(1>
l) (
d^ ^ *1 (d^l>) 2
\a(ff1) ^rod) 2
d^X> d ^ D J
d <3?
— sin φ 4_ |^(i) e
!> d? (1) ^ 2
(d^°)2 ^ l
dp (1) d^ 1 } >> i
~~
d*<2> ß 1
d ^ n df(1> l
(2) d" 'ß*1 _|_
(d^ ( 1 ) ) 2 ^
£<2> ^ 2
^1
+
I
|^,4eJ^
I "(2) c ,
■ « < . > .e;2 d V 2 > 2

+ a (d^>)
ft)2 ft)2 ϊ
sin 0
[d^ n
dp (1
(dpa))2 d?> > dp J a a)
dS2
— cos 0
fdkPJ -
a ) J ^ (( l )
L h<l> >
" w
A(D _iL _il_
.L A< (1) (1) +|a-,Ä »€2
d ?,(1) d? ^ *2 /(Jd„â °
>)\2 ~ K
l d^ d9 J
dki2) Ω2 dß 2 ß1 0\ de" 33 -" | dp<2>
άφα) άφα) kr
2
(d^n)
1,(2) _ ^
Äl
/dW
n
^ » /dl ^^ D ^
!^1_ I
\
-<2)
a
"
^ a ) ' 9' 2 / d ^ a )
' d 'Arrl·»
a £l
(d^>)2
where
Λ_ - j±_ . -d) - jß|_ _ jßf_ , -(2) - d ^ (1.38)

d^(1> άφα άφ{1) άφ{1 3
άφα
denote the absolute rotation rates of the moving frames in the fixed coordinates.
These equations can be reduced into t w o ·
*?■ cos ψ
dft)1 ft)2 ft)2 άω' ft)1 ft)2 1
a> 2 a) (1) sin ψ
(dp ) d? d^ [(d^) >) ^ d^ a ) dp (1)
(1D>k2
2 >
d^( dk™ ft)1 S2 ft)2 1

+ U (1) , d^ 1 ".«1 COS ψ
d ^ ni ) /dWî > ^ ^1 (d? ) a) 2 «21 } -d ^ a ) d ^ a )
{dk?> S 2
— sin ψ - - ^ 4- *«> d(°2 4- k^ — n ~^-
[άφα) άφα) ^ 2 ( d ^ n ) 2 d^ d^nJ
2)
_ Jl_ _ßf_ , f-(2) d / ^ - Idg» ,- < 2 ) τ>(2) - , d y
= k{2) (1) η €l (1) U ,6i; (1> 2
d^> d^ ~+~ Γ ' < ¥ ' |d^ ^ ' (d^ )
d£<2) Ω
-
1
|_ A<2)
Ω
**
2
n\
""l I I ~<2) _d^_
"^3 -
" |I d
"Y^
2)
■ -<2) ~ dy2)
2
(d<p(1))2
άωι ω2 ω\ άω1 ωι ω\
— sin ψ + cos ψ
(1) 2 T)
{(dp ) ~~ W^ <¥ J [(d^ ( 1 ) ) 2 d ^ d ^
i> 4 ^ ;
+ U (1 \ άφα) 1&2 + sin ψ
[ d ^ in) d^<
Λ™<ι> ^ *i ( d ^ ° ) ,22 *2
2
df^df^J
d n 2
*2 ω α> d'af
"i2 _a±_ _ω^
(1) _J_ I ^(1)
deg33 e
U
cos ψ α) 2
[άφ άφα) ^ (d? ( 1 ) ) 2 ^ * d^ a ) άφα) + r d^ ]
Μ^ η ' 2|
_^! ^ L · _L ^<2) 5 f i e =T L ^ ( 2 ) D<2) I N d2y><2)
Arn^ Arn^ ^ \ U
' df(1) ' 2
|dâ) ^ U
' ' 2
' ( d ^ ( 1 )) 2
d£| 2)Ü Jβ^2 _ ^<2> JL· J L , f-<2> ^ 5 L Ϊ ] d j ^ _ - ( 2 ) . - dy 2 >

d ^ *> d$?(1) * d?>a) d ^ ° ^ \ ' d p a > ' 2 )d^ ( 1 ) * (dâ))2
Thus the derivatives of ΊΠΤΪ) and ΊΠΤΪ) can be determined b y :
Cx Ofe{2> - kiiy) sin 0

c2 Ck(22) - k^) cos 0
(1.39)
(d? ( 1 > ) 2
(k[2) - *{1>)cos 0 cx
2>
άω 1 (*{» - ^^ )sin ψ c2
(1.40)
(d^ ( 1 ) ) 2
vhere
Cl = - 9Ri2) -^— — = ^ - -^— 4- ω<21) >δ(2) —a ) l· -=^_ e

d^cl> d^ a> d ^ n d^ a d? ' d^°
+ [ ^ » ( β ^ , ^ , ο + ä<2> · έ 2 ] ^ ξa ) ^2 + cos ψ ^ ! Λ2 ; ^ ^
(d? )
d ( 1 ) d ( 1 )
dki" S 1 Sl ω
+ sin ^ ( Ä « » _ * « > ) > . d ^ uu - 2 1
+ d ^ n d^ a ) d ^ » d?>a> d ^ d^ + (1.41)
(1.42)
Ωι Ω2
Subsequently, the derivatives of T-Q) and -r-j^ with respect to ^ n will be
J^n 2
JLiL
(1) n
J-m) d^> (1) - (5<2\*<2\ö
dy 2 )
(d^ ) df d^ 'dp ' *
(d^>) 2
1 2
deu ω (ο\ 1 2
+ COS 0 + sin ψ da>(1) 2 ω1 ω\ 1
[(d^(1>)2 άφα) dpa)J [(d^ ) d?>(1) dp a )
(1.43)
2
dß J ^ J ^ i ^ n ' ^Λ^<1>-c2]_ r^-0(2) '5tt) -,2 ^ j|»£i2
(d^n)2 d<pa) d<ffl)
,e
^ 2 ,e
(d^>)
ί dS1 ω2 ω\ da>2 ωι ω\
sin 0 (dp a ) ) 2 + cos ψ
dp a ) dp a )
(1.44)
fttz
^^ Tl+<JiT
Fig. 1. 6 An illustration of the moving frame before and after

the contact point moves a distance d5(2) along CPP on Σ (2>
With these values, further analysis and calculation of the changing rates of second
order contact parameters can be carried out. From Eq. ( 1 . 21) we have
άθα) _ (jä_ dS2 _ _S*_ άΖι \ // d s ^

(1.45)
άφ ~ \d(ff (d<pa>y άφα) (dp (1) ) 2 j l\ άφα)
α) iy
d0 (2) Ω1 άΩ2 Ω2 άΩι \ / ( d 5 ( 2 )

(1.46)
dp (1) \ d ^ (dp ( 1 ) ) 2
n α)
d ^( a ) ) 2 ) / \ d ^ a )
άφ αάφ
Figure 1. 6 illustrates the principal directions of Σ ( 2 ) before and after the contact
point moves a distance d5<2) along the CPP on Σ ( 2 ) . Obviously, when the changing
rates of the directions of CPP are to be determined, the rotation of the moving
frames has to be taken into account. T h u s the geodetic curvatures of CPP on both
surfaces Σ ( 1 ) and Σ ( 2 > can be expressed as
_ d ^ ω\ /d5 ( 1 )
(1) (1.47)
ds "*" άφαΊ d<ffO
d0(2> , Ω\ /d5 ( 2 )
(1.48)
dsi: +
άφα)»I άφ{ α)
Ι άφ
The influence of the geodetic curvature of CPP on the tooth bearing is illustrated in
Fig. 1. 7. If the value is large, the contact situation changes quickly in the meshing
process. In addition, interference between tooth surfaces may occur in some cases.
Fig . 1 . 7 . The influence of the

geodetic curvature of CPP on
the tooth bearing
Differentiating both sides of Eq. ( 1 . 2 3 ) , the higher order angular acceleration of

gear 2 relative to gear 1 can be calculated as follows:
d2Rw -,„> dfla> de3 ά%
I '(dy^) 2 '* 3 / 2
1 'df^'dfW +
1 ' '(d^ l >) 2 /
= β) «¥» d^-ä ay» de3] r(-„>da«> -| dy»
;«>
dy 2 ) _ ' ' d ^ 0 (d^») 2 ^ (de*°)2 d^ l) / ^ ' d ^ » ' V (d^ n ) 2 J
(d^»>)3
(5<2\ Ä«>, e3)
(1.49)
where
d2e3 d*i» » _ , . ( l , _ d » <1> J "l L i i L

(dî>) 2 [d^l> d^11) "Γ *1 (dy^>)2j *i: d^ > d^l>
d/fe|l> S2 2
de.
ki2l> dS 0 2
d<!
1(1) _Ϊ1_ Jif2_ . "(I) χ 3
[d^° d^ l)
(d^ ) ] d^> d^1 d^>
(1.50)
d2# άω] ω1 aex *»2 " l i L A 1 i 5 x d ^ <l>l)

n 2
( d ^ 1>V
) (d^ n ) *1 +
rrl^D^Z l> Hß)<l>
H»<1>
d^ df>a> ' (dp a) ) d^° d^ d^
(1.51)
The influence of this parameter will make the transmission curve asymmetric as il-
lustrated in Fig. 1. 8. If this value is large enough» the transmission curves of neigh-
bouring teeth cannot intersect with each other, which leads to the transmission being
Gear Lag
Fig. 1. 8 The influence of higher order angular

acceleration on the transmission performance
performed by the top edge of the tooth during a certain period. These will not only
be an apparent increase of noise for a gear pair with this kind of transmission curve,
but also the service life will be reduced. So the value of this parameter should be
strictly controlled by means of optimization.
The analysis of the rate of change of the instantaneous contact spot needs now to be
carried out. Differentiating Eq ( 1 . 28) leads to
4 / i ) C ( # ( 2 ) ) 2 - Ra)R(2)cos 2ψϊ
2) 2)
I Ud£< dki \ I dki n
dkiUl)A\ :
73(1)
/g
l
U/Z
2 r><2)
KXK
l 2 sin 2ψ
\άφ α)
άφαη \d<pa) dcff^j
(1.52)
άφα) 4C(# ( 1 ) ) 2 + ( # ( 2 ) ) 2 - 2Ra)Ri2)cos 20D
where
άψ Ω\
(1.53)
άφα) d^° άφ^
is the rate of change of the angle between ex and e1# This equation can be obtained
from cos ψ = ex · e1# From Eq. ( 1 . 30) we get
dA<2) =άλ^__ _άψ_

(1.54)
άφα) ~ d ^ n άφα)
Fig. 1. 9 The influence of the

rate of rotation of the major
axis of the contact ellipse on
the tooth bearing
As for the influence of the rotation of moving frame on the direction of C P P , the ro-
tation of moving frame has also to be taken into account when the changing rate of
the direction of major axis of the contact spot is concerned. T h u s the rates of rota-
tion of the principal directions of the instantaneous contact spot with respect to the
arc length of CPP on both surfaces can be written as
(1.55)
^ ^ nn ^'
dd<^ α
άφα) )/άφ{1)
Ί/άφ α
(1.56)
^ d ^ n "^ άφα> Ιάφα)
These parameters are valuable for understanding the forming process of tooth bear-
ing (Fig. 1. 9) and for a further analysis of the lubrication condition between the
tooth surfaces.
The rates of change of the principal relative curvatures can be obtained by differenti-
ating Eq. ( 1 . 3 2 ) ,
Q/Zl
a = Q / g l c o s 2 A (2) 4 - 2a ) sin 2 A(2) — * c o s 2 A (1) — 2 n ςίη2 Α(1>
dp > d^> * ^ dp * dâ> * d^ *
HA(1) rU<2>
+ 2/?<1>sin 2A«> J J J . _ 2 Ä ( 2 > s i n 2 A «> ^ _ (1.57)
21)
d/fe<
^2 d*{»
""-1 · 2 5<2> l d*?>
""* „ „ 2 1(2) _ "*1 «.; n 2 1(1) _ "*2 -„,.2 1(1)
d^ U +
d^n dÛ
g
d^» * d^'> * *
+ 2*<2>sin 2A«> ^ L . _ 2jR < 1 ) sin 2A»> g f c (1.58)
Thus the rates of change of the length of major and minor axes of the contact spot
can be obtained as follows ·
1 /t d * < 2 1 ) / d s a )
a
di > 2 #21> dÎ>/d^l>
d/2 1 /2 c /dia>
*221) l>
(1>
di 2 <V /d (1.59)
di <2> 2 *i21> djWd?*»
d/ 2 J_ /, d£ 2 21> /ds <2)
ds <2> 2 *i"> dfWdj*»
άί
The influence of -T-jfi o n the tooth bearing is illustrated in Fig. 1. 10.
This parameter has some influence on the load carrying capacity, and can be im-
proved by changing the pressure angle of the cutter.
Fig. 1. 10 The influence of the

rate of change of the length of
major axis of the contact spot
on the tooth bearing
As shown in the analysis detailed above, with the parameters obtained, we can get a
clear understanding of the gear engagement process, and positively evaluate the con-
tact quality.
1. 7 EXAMPLE CALCULATION
A pair of hypoid gears in mesh is taken as a calculation example to illustrate the ana-
lysis method presented in this chapter. For the drive side, two set of parameters are
presented below to show how the third order geometric parameters influence the con-
tact performance of the gear pair. The basic parameters a r e :
Tooth Number of the Pinion: 6

Tooth Number of the G e a r : 37
Pitch Diameter of the G e a r : 305.358718 mm
OffSet. 35 mm
Face Width of the G e a r : 42 mm
The parameters at the reference point on the convex side (drive side) of the gear are
as follows:
Ri2) = 4 0 . 80467 i + 124. 80318 j - 31. 63147 k

β! = 0 . 823105 1 + 0. 558167 7 + 0 . 104631 k
e2 = - 0. 001597 1 - 0.181970 j + 0. 983303 k
£<2> = o. 00682051 k{22) = 0. 00381926

2
k[ \ = - 7. 00617* - 6 k?\ = - 7. 55212* - 6
k?\ = 1. 25615* - 5 k?\ = 1. 65271* - 4
The parameters up to the second order at the reference point on the concave side
(drive side) of the pinion are prescribed, so they have one and the same values for
both Set 1 and Set 2. These a r e , as follows:
# ( 1 ) = 5 . 80467? + 151. 434967 ~ 31.19278*

*\ = - 0. 472468? - 0.172474? - 0. 864307*
*2 = 0. 674001? + 0. 561174; - 0. 480422*
jfc = - 0 . 0276636 k™ = 0. 00550764
The third order pinion tooth parameters a r e :
Set 1: k[)l = 1. 90500* - 3 k[\\ = 1. 27269* - 3

*2i = - 3. 70143* - 5 k£l = - 2. 35951* - 5
Set 2: k[\\ = 1. 89386* - 3 k[)\ = 1. 26432* - 3

*2Ϊί = - 4. 45943* - 5 k£l = - 2. 81254* - 5
The second order contact parameters, which are the same for both s e t s , are illustrat-
ed below :
υ=0°, l2 = 17. 6571mm, κ = 17. 9248°, * \L2 =- 0.0004
dsa) ds(2>
j - ö ) = 22. 17495mm/rad, - p ^ = 10. 52401mm/rad
ls
It should be pointed out that a certain amount of ( ,ZD\2 desirable because it serves
the function of crowning.
The third order contact parameters for Set 1 are given b y :

G (1) = - 0 . 0252613rad/mm, G (2) = 7. 61166e - 4 r a d / m m , Q(1) = - 2 . 3 3 5 9 9 7 m m ,
Q° 0. 646273°/mm, dy 2) = — 7. 83614* - 5,
d/2
(d^1>)i -(f) = 7. 24728* - 3
as
The amount of gear lag with respect to the pinion's rotating angle is illustrated in the
following Table 1 . 1 . In this table, the ideal set of values indicates a parabolic curve
according to the desired crowing value. The cubic set of values is the result of third
order contact analysis, and the third row shows results from the T C A program.
Gear Lag
Fig. 1. 11 Tooth bearing and transmission graph of Set 1
Table 1. 1 Gear Lag Relative to Pinion's Rotating Angle

Pinion's Rotating Angle -30° -20° -10° 0° 10° 20° 30°
Ideal 11.31" 5. 207" 1.257" 0 1. 257" 5. 027" 11.31
Gear Lag Cubic Curve 10. 92" 4. 912" 1. 242" 0 1. 271" 5.141" 11.70"
TCA 11. 09" 4. 946" 1. 244" 0 1. 273" 5. 181" 11. 90"

The contact parameters from TCA are illustrated in Table 1. 2.
The tooth bearing and the transmission graph from the T C A program are illustrated
in Fig. 1.11. As shown in the figure, the contact characteristics changes slightly in
the whole meshing process, and the transmission graph is very close to the ideal one
which can be obtained using values listed in Table 1. 1.
Table 1. 2 Contact Parameters

Φ» -30° -20° -10° 0° 10° 20° 30°
X -0.09320 -0.03031 -0.00455 0 -0.00220 -0.02337 -0.08643
Y -5.29306 -3.57301 -1.81070 0 1.86450 3. 78694 5.76964
h 17.5595 17. 6028 17. 6364 17.6571 17. 6623 17.6508 17. 6228
K 14. 966° 15.827° 16.809° 17. 925° 19.186° 20. 597° 22.160°
Gear Lag
Fig. 1.12 Tooth bearing and transmission graph of Set 2

The third order contact parameters of Set 2 are illustrated as follows :
G(1> = - 0 . 0435235rad/mm, G (2) = - 0 . 0776039rad/mm, Q ( 1 ) = - 2 . 32480°/mm,
d3o(2> al
Q<2> = _ o. 6 2 2 6 9 4 7 m m , \ = - 6 . 62160* - 4 , ^ f > = - 0 . 483231
The amount of gear lag with respect to the pinion's rotating angle are then given by
the values shown in Table 1. 3 below :
Table 1. 3 Gear Lag with Respect to Pinion's Rotating Angle

Ideal 11.31" 5. 027" 1. 257" 0 1. 257" 5.027" 11.31
Gear Lag Cubic Curve 8. 042" 4. 058" 1.136" 0 1. 377" 5. 995" 14.58"
TCA 8. 156" 4. 081" 1. 137" 0 1.379" 6.017" 14.71"
The tooth bearing and the transmission graph from T C A are illustrated in Fig. 1.12.
The relevant contact parameters are listed in Table 1. 4.

Φ» -30° -20° -10° 0° 10° 20° 30°
X -1.35276 -0.57281 -0.13678 0 - 0 . 12553 - 0 . 4 8 2 1 9 - 1 . 0 4 3 3 9
Y -5.69225 -3.75004 -1.85498 0 1. 82001 3. 60870 5.36860
h 20. 8852 19. 6705 18. 6013 17 6571 16.8212 16.0800 15.4221
K 14. 925° 15.823° 16. 826° 17 .925° 19.110° 20. 373° 21. 703°
The parameters at the reference point on the concave side (reverse side) of the gear
are as follows:
Ri2) = 2 5 . 04987 ι + 128. 89282 J - 31. 63147 k

ελ = 0. 702075 ϊ + 0. 698326 ~j - 0. 139401 k
ε2 = 0. 237066 ϊ - 0. 413798 ~j - 0. 878960 k
k[2) = - 0. 00580856 W = 0. 00512128
k[2X = 2. 45029e - 6 k?X = - 2. 78628* - 5
k?\ = - 6. 30456* - 5 k?\ = 2. 61933* - 4
The parameters up to the third order at the reference point on the convex side (re-
verse side) of the pinion are presented as follows:
Ra) = - 9 . 95013 1 + 155. 52460 J - 31.19278 k

*Ί = - 0. 472875 ~i + 0.150026 7 + 0. 873635 k
*2 = 0. 578667 ~i + 0. 797734 7 + 0 . 1 6 9 6 0 1 k
k[l) = - 0. 0350131 k?> = 0. 00509814
kl\\ = - 1. 30089* - 3 k[]l = - 7.10697* - 4
k£\ = 4. 90912* - 5 kgl = 3. 61144* - 5
The second order contact parameters are illustrated below :
2
f=0% l2 = 17. 9480mm, κ = 20. 6035% dy
ΤΤαϊγ = °· 00
°4
ds(1) ds<2>
dp 0 = 21. 0733mm/rad,
-^ϊ) jd?- (1^ = 8. 77601mm/rad
The third order contact parameters are given by:
G(1) = 0. 0235225rad/mm, G<2) = 7. 87308* - 4rad/mm, Q(1) = 1. 226467mm,
d3<z><2) dZ
<2>
Q = - 1 . 350887mm, (dJ1))8 = ~ 1. 55964* - 4, ^ = 1. 05189* - 2
The amount of gear lag with respect to the pinion's rotating angle is illustrated in
Table 1.5.
Table 1. 5 Gear Lag Relative to Pinion's Rotating Angle

Ideal 11.31" 5.027" 1. 257" 0 1. 257" 5. 027" 11.31
Gear Lag Cubic Curve 12. 08" 5. 255" I.285" 0 1. 228" 4. 799" 10. 54"
TCA 12.19" 5. 278" 1. 286" 0 1. 230" 4. 826" 10. 69"
The contact parameters from TCA are illustrated in Table 1. 6 as follows:

<p™ - 3 0 ° -20° -10° 0° 10° 20° 30°
X -0.12528 -0.03919 -0.00546 0 -0.00375 -0.03401 -0.11961
Y -4.01371 -2.79949 -1.46449 0 1. 60079 3. 34217 5.22547
h 17.8499 17.8952 17. 9272 17 9480 17. 9605 17.9683 17.9755
K 15. 078° 16. 772° 18.612° 20 .604° 22. 750° 25. 051° 27. 498°
The tooth bearing and the transmission graph from the TCA program are illustrated
in Fig. 1. 13. As shown in the figure, the contact characteristics changes slightly in
the whole meshing process, and the transmission graph is very close to the ideal one
as listed in Table 1. 5.
ΨS»
Gear Lag
Fig. 1.13 Tooth bearing and transmission graph of the reverse side
From the examples we know that the solutions found from third order contact analy-
sis compare quite well with those from the T C A programme, no matter how the con-
tact situations change. The calculation examples show a great importance of third-
order contact parameters to gear pair performance. It is not true that controlling
third-order contact parameters is not necessary in practice. On the contrary, in order
to keep the contact situations obtained from local synthesis substantially unchanged
in the whole mesh process, some third-order contact parameters should be strictly
controlled.
1.8 CONCLUSION
An accurate analytical method for the analysis of the contact situations between a
pair of combined mismatched tooth surfaces is presented in this chapter. From the
examples of calculation it has been demonstrated to be a reliable and valid means for
the investigation of the performance of mismatched surfaces. The solutions found
from third order contact analysis compare well with those from the TCA program,
though the analysis is carried out at only one point. Since the results are found in
parametric form, an objective funtion for optimization can be directly composed and
no further analysis is required. In this w a y , the error of the member gear's rotation
angle can be held within 1-2 seconds, whilst the centre of the contact pattern and the
second-order contact parameters can be predicted, and the other third-order contact
parameters, such as the geodetic curvature of CPP and the changing rate of the
length of major axis of the contact ellipse, can also be strictly controlled. T h u s a gear
pair with better comprehensive contact performance can be obtained.
2
A Direct Method for Calculating

Geometric Parameters
of Tooth Surfaces
up to and Including Third Order
2.1 INTRODUCTION
In Chapter 1 the geometric parameters up to the third order of tooth surfaces were
assumed to be known. This chapter will present solutions to the chapter title prob-
lem by analysing the relationships among the geometric parameters of both the gene-
rating and the generated surfaces and the relative movement between them1-10-1. Based
on the theoretical analysis, an algorithm is obtained. In order to include all the
working methods used by different bevel gear generators and grinders, both the rela-
tive angular acceleration between the generating and generated surfaces and the rela-
tive movement between their axes have been taken into account. For individual ma-
chine tools which do not have the corresponding mechanisms, users can simply set
these parameters equal to zero, or delete the terms containing these parameters from
the formulae. Although the geometrical nature of the generating flank used in the
manufacture of hypoid gears is quite simple, an analysis of the geometry of the gene
rating flank in a general form is still presented in this chapter, so that the method
suggested can be applied to various situations1-16,17·1. The geometric parameters of a
circular cone, which is widely used for generating hypoid gear tooth surfaces, are di-
rectly expressed in explicit form, so that the readers can easily put the method into
practice. A distinguishing character of the algorithm is that all the practical calculat-
ing formulae are given in an explicit form, so that a rapid response can be expected.
A practical numerical example is also presented at the end of this chapter to demon-
strate the calculation procedure.
It is known that the analysis of the geometrical parameters of the surface being gen-
erated up to second order as well as the algorithms have long been offered by other
authors1-6'7-1. As the foundation of a further analysis, the former is also included in
this chapter, however in a simpler and more direct way.
2. 2 T H E C U R V A T U R E TENSOR O F A S U R F A C E
The main mathematical means applied in this chapter are curvature tensor and mov-
ing frame. Since moving frame has been discussed in detail and given a full demon-
stration in Chapter 1, this is therefore not to be treated as a new concept and dis-
cussed in detail. The concept of curvature tensor is presented in this section. It
should be pointed out that the curvature tensor referred to in this book hereafter is
not the Riemannian tensor, but the gradient of a field of unit surface normal vectors.
Suppose there exists in 3-dimensional Euclidean space a smooth surface. The posi-
tion vector of a certain point on the surface is denoted by r = r(ux ,w 2 )· "i and u2 are
the parameters of the surface, and on the considered surface patch, \d1rXd2r\ Φ 0.
Thus the lines compose a normal net in the local area being considered. The unit sur-
face normal vector n = dx r X d2 r/ \ dx r X d2 r | is a function defined in a certain domain
of wi« 2 -plane. Representing the convariant base vectors as r{ = d{ r (i = 1 , 2 ) , the
contravariant base vectors can be expressed as
C - l V r j X n
** = ,- - - N 0,; = l,2;i^7') (2.1)
Oi,r2,w)
It is easily shown that

GEOMETRY PARAMETERS OF TOOTH SURFACES 31
r f V = e.-,· (2.2)
The curvature tensor of the surface is defined as the gradient of the field of the unit
surface normal vectors, expressed as follows:
X7n=?d{n (2.3)
where i is a dummy index. V « is a sum of two diad. The left and the right vectors in
a diad are denominated as the forward and latter a r g u m e n t s , respectively. When a
vector makes a scalar product with a diad from the left, we take the result of the
scalar product of the vector and the forward argument of the diad as the coefficient of
the latter argument. Whilst a vector makes a scalar product with it from the right,
we take the result of the scalar product of the vector and the latter argument as the
coefficient of the forward argument.
Assume that c is an arbitrary curve on the surface, s is the arc length of the curve.
According to the definition of gradient it is known
an ar __- ,Λ jN
Ts = dS'Vn (2
·4)
which can be proved immediately from Eq. (2. 1) and the following formulas·
ar _ dui - d^2 - an _ du± d n au^ dn ( .
as as 1 as 2 9 as as d ul as d u2
When Ui~ and w 2 -coordinate curves coincide with the lines of curvature of the surface,
the curvature tensor can be expressed in the form
Vw = — klelel — k2 e2 e2 (2. 6)
where el and e2 are unit vectors of the principal directions, £i and k2 the principal cur-
vatures respectively corresponding to ex and e2 . Obviously, it is a symmetric tensor,
i. e. the order can be reversed without changing the result when it makes a scalar
product with a vector. This is held valid under coordinate transformation.
2. 3 GEOMETRIC PARAMETERS OF THE GENERATING FLANK
Although the function r ( / ) = r ( / > (w 1 ,w 2 ) of the generating flank Σ ( / > is supposed to

be known, a suitable form to describe Σ ( / >
in a neighbourhood of the reference point
is required to be worked out. The authors believe that the most convenient forms to
use in a further analysis and calculation are the principal directions, principal curva-
tures and their partial derivatives with respect to the arc length of the curvature line
at the reference point. It is supposed that r ( / ) = r ( / ) ( w , i ; ) is a function of C3 class,
i. e. it has continuous partial derivatives up to the third order. First, the unit normal
of the generating flank Σ ( / ) at the reference point M can be expressed as:
:c/> _ ~(/>
ήη vX ^</>
r^/VD (2.7)
whe D = EG - F2 (2.8)
here E = r*, F = rurv, G = r\ (2.9)
Secondly, normal curvatures of Σ along w-and z;-lines take the form
(2.10)
E9 v
~ G
- e?1
Fig. 2.1 The tangent directions
of Σ ( / } at the reference point
and the geodetic torsion of Σ ( / > 3 ^ ^ «-line can be represented by

(f) EM - FL ,
nf) = -=— (2.11)
E VZ)
In the above equations L = ruu · nu \ M = ruv · n(f), A'' = ~rvv · ησ) (2. 12)
Then» denote the directed angle from ru to rv by Θ (Fig. 2. 1) , and the directed angle
from the unit vector of the first principal direction at M t o r„by θχ . From Euler's and
Bertrand's theorems it is known
k<f> = k[n cos 2 θχ + k\n sin 2 θλ (2. 13)

n 2 n 2
£</> = k[ cos (0 + Θ0 + k\ sin (0 + Θ0 (2. 14)
f)
r<'> = - ( k[ - k(2f)) sinfli c o s ^ (2. 15)
where 0 = tan-1 ^ = - (2. 16)

F
From above equations we have
-, 2r</)sin20
1
θγ = ■$- t a n " (2.17)
2 *</>_ £</>_ r</>sin2i
T h u s the unit vectors of the principal directions can be obtained as follows :
e[n = - p z (cos θ1 ru - sin θχ n ( / ) X rM) , ~e\n = n(/) X ^ / > (2. 18)
The values of the principal curvatures can be obtained by using Eqs. (2. 13) and (2.
14) together.
The second order parameters of the generating flank have been analysed so far. The
third order parameters will be analysed below. From Eq. (2. 8) >
Du = EUG + EGU - 2FFU, 3,(VZ)) = -^— (2.19)

2 VD
T h e n , from Eq. (2. 16) we have

H Fdu(Jp) - FUJD
(2.20)
du F2 + D
T h u s the partial derivatives of kif), kif) and r^ /> with respect to u can be written as
follows :
d k? > ELU - EUL d k? > GNU - GUN

(2.21)
du E2 du
drjn = EUM + EMU - FUL - FLU - {EM - FL) fa (In \fl)) + 3, (In £ ) ]
3u
E>/D
(2.22)
The partial derivative of the directed angle θ with respect to u can be expressed as
λ
' ^£1 sin2 θ + r</> s i n 2Θ | ^ | (*/> - *<'> - r<'> sin 20)

i d U du
— r y > sin 2 Θ I — ^— sin 2 0 — 2 r(un cos 20 — , ,

9θι du du du d U/ J
dU
2 2
(^) + («Ό + 4 (r< / >) 2 sin 2 0
2k?> Kn + 2 (*/> - * / > ) r<'> sin 20
(2.23)
Similarly, values of - j — , - 5 — , - 5 — ,3— and -τ— can be obtained as follows:

d V d V d V d V dV
Dv
Dv = £„G + EGV - 2FFv9 3ν(7ζ)) (2. 24)
\[D
FromEq. (2.16),
20 Fdv(\/D) - Fv\fD
dv F2 + D (2.25)
The partial derivatives of k{uf)9kif) and r^ / ) with respect to v will be

dk </) ELV - EVL dk(vn GNV - GVN

E2 (2.26)
dv dv G2
drjn = EVM + EMV - FVL - FLV - {EM - FL) fa (In 7 D ) + a, (In £ ) ]

dv
E \/D
(2.27)
The partial derivative of the directed angle θχ with respect to v can be expressed as
d
-^l sin 2 0 + r<'> sin 20 f ^ l (*<'> - *<'> - r<'> sin 20)
a ^ a *(/)
^ - ^ sin 2 0 - 2ri/>cos2^ l Jl
3 0! at; dv at; dv
at;
( « / > ) , + ( « / > ) , + 4 (r^>)2sin20
2£< /) *<'> + 2(£< / ) - *<'>) Γ / > sin 20
(2.28)
On the other h a n d , by using moving frame theorem, the partial derivative of klf)
with respect to u can be expressed as follows:
dkif[= d (k,f) cog2 ^ + k,f) sin2 e^

du du
9θ1
cos 2 θχ + ^ - sin 2 θι - (k[n - *<'>) sin 20x
aw du au
n
dk\ ~i a \
z
ω2 3su
2
dsu Zz asu -z— cos 0X
au
Ι ^ sin 2 0, - (*<'> - *<'>) sin 2 0 ^
+ ω1 ^5« ω2 dsM
where d5M denotes the differential length of u line, ω1 and ω2 the projection of dsu on the
moving frames. The other partial derivatives of kif) and k^f) with respect to u and v
dk[n dk[n dk\n
can be found in a similar way. Let ^ ί ^ , k[fJ, k\*i and ^ ^ denote —z:—»—^:—»—z:—
or or or
and —^:—, these equations can be written in the form :
ω2
3
-ψ^-= ( *</> cos 0, + k&> sin Θ0 \[E COS2 ΘΧ + ( k&> cos 0,
+ k¥J sin 0,) V i sin 2 θι - (k[n - klf)) sin 20, | ^ (2. 29)
^ ί ^ = [ Aft* cos (0 + Θ0 + k\{? sin (0 + 0 , ) ] T O cos 2 θλ + [ *ft> cos (0 + 0 t )
+ *&> sin (0 + 0 j ) ] T G sin 2 0, - (k[f> - *K>) sin 2 0 χ | ^ (2. 30)
^ - = ( *</> cos θι + k[Q sin 0X) VÊ COS 2 (0 + Θ0 + ( *&> cos 0X + jfe&> sin Θ0
d U
4E sin 2 (0 + ^ ) - (*Κ> - ΛΚΟ sin 2«? + < v ( f ^ + | ^ I (2.31)

\d U d U I
d
- ^ = [ k?i cos (0 + θ{) + Kgi sin (0 + (?!>] 7 G COS 2 «? + 0,)
ill
+ [ *&> cos (0 + 0X) + k& sin (0 + 0 X )] >/G sin 2 (0 + 0X)
- tk?> - k\f^ sin 2(0 + ii) [|^ + 1^1 (2.32)
By using the above four equations together, the partial derivatives of the principal
curvatures with respect to the arc length of the lines of curvature (k[fJ, k[fJ, k\ft?
and ^2^) can be obtained.
The above discussion concerns a general situation. For some other situations, the
above formulae may be greatly simplified. For instance, if the generating flank is a
helicoid surface, as used in hobbing a worm wheel, and the t;-lines coincide with the
helixes on the surface, all the partial derivatives of £ , F , G, L , M and N with re-
dk n dk n
.„ v , ~, t » v *ήη 30 ddx
spect to v will be equal to zero. Therefore —z— = — — = — — = ^— = —— =
dV dV d V d V d V
0. Thus Eqs. (2. 30) and (2. 32) can be simplified to
k&> cos (0 + 0L) + £<{2> sin (0 + 00 = 0 (2. 33)

k&> cos (0 + Θ0 + k&> sin (0 + Θ0 = 0 (2. 34)
It Σ ( / > is a surface of rotation and it is assumed that w-lines are along the longitudes
of the surface and t;-lines along the latitudes, both families of parametrical lines are
the lines of curvature of Σ ( / > . Thus not only F = M = 0, but also Ev= Gv= Lv =
Nv = 0 hold for every points on Σ ( / ) · Since Θ = — and θχ = 0, k[fAy and ktfi can be di-
rectly obtained from Eq. (2. 2 1 ) , and *&> = jfe&> = 0 from Eq. (2. 26). If Σ ( / ) is a
circular cone, as used for generating Gleason spiral bevel and hypoid g e a r s , and u-
lines coincide with the straight generatrixes of the cone and i/-lines with the lati-
t u d e s , the structure of the generating flank is so simple that its geometric parame-
ters can be directly expressed in the form:
COS^p
*</> = 0, k\n = ±
~R~
</) (2.35)
} f) 2
*ft = - (k< ) tan ψρ
Fig. 2. 2 The principal directions on circular cone

generating surfaces
where the upper sign in " ± " i s for the outside of the cone and the lower the inner
side, <f>p denotes the pressure angle of the c u t t e r , and R the radius. The direction of
e\n and e\n are illustrated in Fig. 2. 2.
38 A D V A N C E D THEORIES OF HYPOID GEARS
2. 4 SECOND ORDER GEOMETRIC P A R A M E T E R S
The contact situation of two surfaces Σ ( / ) and Σ ( 1 > in contact with each other along
an instantaneous contact line is shown in Fig. 2. 3 , where a ( / ) and aa> denote the unit
vectors of the axes about which Σ ( / > and S ( 1 > r o t a t e , Rify and Ra) the position vec-
tors from the points fixed to their axes to a certain point M on the instantaneous con-
tact line in the fixed coordinte system. Σ ( / > rotates about a fixed axis, with the rota-
tion angle oi<jftf) ; while Σ ( 1 > rotates about a moving axis, with the rotation angle of
<pa) . Since the axis of Σ α ) makes only translating movement, a (1) is a constant vec-
tor. L is the vector from the point fixed to the axis of Σ ( / * to the point fixed to the
axis of Σ α > . Both <pay and Lare functions of <ftf)oi class C 3 (having continuous deriva-
tives up to the third order).
Fig. 2. 3 . Two surfaces in contact along a line
As shown in Fig. 2. 4 , e\n and^K* denote the unit vectors of the principal directions
of the generating flank Σ ( / > at point M. Suppose
is the unit inward normal of Σ ( / > at the point, e[l) and e^ denote the unit vectors of
the principal directions of the generated surface Σ α > > with
ϊ<ι> = e^ X i«>
being its unit outward normal. T h u s along the contact line
holds, ϊχ denotes the unit tangent vector of the instantaneous contact line at point M ,
while t2 = n ( / > X ί1# ψ is the directed angle from e[f) to e[l) , while 0 denotes the di-
rected angle from e[n to ii and β the angle from e[iy to ~tx .
Since the geometric parameters of the generating flank can be determined using the
method presented in the above section, hereafter e[f), e{zf)i k[f), k\n, Pify> p\n*
f) n (/)
and the partial derivatives of k[ and h\ as well as the curvature tensor V w are
supposed to be known. Let
άφα)
Ulf
άφσ)
denote the instantaneous rolling ratio, and as the relative movement between Σ ( / >
Fig. 2. 4 The angles between

principal directions
and 2 ( 1 > i s supposed to be k n o w n , ulf is a known function of <pif) . Without losing

aoffy . d
generality, suppose , = 1 , which means the operator , ,n is identically equal to
the operator -j- . Let v(f) and va) denote the velocities of following of Σ ( / >
and Σ ( 1 > at
point M. They are
-</> = "(/) χ ^(/) (2<36)
(1
5(i> = Ulfa™ X # > + L (2.37)
Hence the relative velocity between the surfaces at the contact point M will be
- = "(I) _ J</> = Uifâ) χ £<!> + Z _ -</) χ £(/> (2# 3 8 )
a ~(/> a ~(i)
Let (/) and (/) respectively denote the velocities at which the contact point M
moves relative to Σdr( (f)
/
* and Σ- ( 1 > in the
dr (moving
1) coordinates rigidly connected to them.
Since both νσ) + j^j-y and t/(1> + | -Tf) are the absolute velocity at which the con-
tact point M moves in the fixed coordinates, we have
a -d) a-</>
inn = d(p
d<fi J7*nu - van (2.39)
3r ( / >
Since S ( / > a n d Σ ( 1 > are in contact along a line, ^ ' ( / ) is multivalued. In order to make
practical calculation possible, hereafter it is supposed to be parallel to e\n, and |sin
(otherwise interchange the two families of coordinate curves; if the gen-

erating flank is a cone and e\f y is along the straight generatrix of it, this condition is
generally satisfied). In a certain neighbourhood |sin θ\ > 0 holds because of the con-
tinuity of the geometric parameters. Thus in the neighbourhood w-coordinate lines
and the instantaneous contact lines compose a normal net. Denoting the arc length of
the instantaneous contact line by 5, the position of the contact point becomes a func-
tion of φσ) and s . Since n ( / > · vaf) = 0 is held for all the points along the instanta-
neous contact line, the following equation can be obtained by partially derivating the
equation with respect to s :
K
ds = βι · V n ( / ) ) · ί α / ) + n ( / ) · (ω<^> X t{) = Pan · tx = 0
(2. 40)
where ω α / > = ulfaa) — a(/> (2. 41)

denote the relative angular velocity between the a x e s ,
pa/> = -a/) . v-</> _ -a/) χ -(/> (2# 4 2 )
From Eq. (2. 40) it is known that Paf} _L h; from Eq. ( 2 . 4 2 ) it is easily shown that
p a / > _L „</> . T h u s Pan // ti9 therefore
paf)
, tx = t2 X n ( / ) (2. 43)
Ml/) I
Imagine there exists a surface which contacts Σ ( / ) and Σ α ) at point M , and along
any tangent direction the normal curvature of the imaginary surface is equal to the
difference between the normal curvatures of Σ ( / > and Σ α ) along the same direction.
This surface is termed as the difference surface between Σ ( / ) and Σ α ) » its curvature
tensor is termed as relative curvature tensor, which equals to the difference between
V w ( / ) and V « ( 1 ) · As the normal curvatures and geodetic torsions of both Σ ( / ) and
Σ ( 1 ) along ~tx have the same value, the relative normal curvature and relative geodetic
torsion along this direction are equal to zero, which means that ~tx and t2 are principal
directions of the difference surface, and tx is an asymptotic direction. Since P ( 1 / ) //

t29 it can be reasonably supposed that
_ pp
VTZ ( 1 ) = V«(/) - - (2. 44)
where slf is an undetermined function.
Partially derivating ησ> · vaf) = w(1) · vaf) = 0 with respect to φσ) leads to
| ^ · V * ( / ) + ~a'n X n ( / ) ) · v«n + n (/ > · | ^ =0 (2. 45)
Substituting Eqs. (2. 44) and (2. 39) into the second o n e , and taking w a ) = w ( / ) i n t o
account, we have
< oZ(f) \ I p(l/)p(l/)\

7,a/>
di;
_L Z</> # _n (2.46)
Equations (2. 45) and (2. 46) can be reduced to
| r £ ! . pa/) + -a/) # pa/) - 5l/ =0 (2.47)
The partial derivative of vaf) with respect to φσ) can be obtained from Eq. (2. 38) as
follows
dv (1/)
^ = Uua^ X Ä - Ulfa™ XL + L+ ω<^> X *<'> + ω<^> X | if^
d . V n ( / ) - ω α / > X W
(/
>) + n ( / ) · (ulfäa) X £<
dp(
(1)
Wl/a X L+ L + ω(1'> X z/'> - a(f) X t / a / ) ) = 0 (2.49)
Substituting Eq. (2. 42) into this equation, we have
-<i/) . p a / ) _ Si/ + "(/) # ( Wl/ ä x P<»
wx/av X L + L + a>a/> X v</> - a ( / ) X ^ a / ) ) = 0
which can be written as
Slf= ί « / > · ρα/> -f ησ) · g a / ) (2.50)
vhere
ga/) = î/aa) χ #<i) _ Mi/aa> χ L + L + ω α / > X νσ) - äif) X vaf)
(2.51)
G E O M E T R Y P A R A M E T E R S OF TOOTH SURFACES 43
T h u s the normal curvatures of Σ ( 1 ) along the directions of ^ a n d ^ c a n be obtained by
k^ = - (ίχ · V t t ( / ) ) · h (2.52)
£ = - ( h · V n ( / ) ) · t2 + S
(2. 53)
lf
and the geodetic torsion of Σ ( 1 > along ti9 as well:
ΓΪ" = - ( i L · V n ( / ) ) · ϊ2 (2.54)
These are the second order differential parameters of 2 ( 1 > w i t h respect to the frame
On t29 n ( / ) ) . In order that the parameters can be used in the algorithm presented in
Chapter 1, we have to express the parameters with respect to the frame composed by
unit vectors of its own principal directions. From Euler's and Bertrand's theorem,
k™ = k{» cos 2 β + k^ sin2/?
k^ =£<!> sin 2 β + *«> cos 2 β
τ£ι> = - £<ι> sin 2ß
A<1> _ A(l)
2
where Ra) = l
g (2.55)
From the above we know the directed angle from ex to ίγ is
(1)
1
β = - | tan" -ΟΓ3ΤΟ) «.56)
The difference and sum of the principal curvatures of Σ α > are
(1>
z,a> _ A(D r-
Ä(i> = *i ** = _ _ H # 5 7) ( 2
2 sin 2p
Hu> = *i +*» = *'. + ' (2.58)

Therefore, the two principal curvatures of 2 ( / > w i l l be
*<» = H ( 1 ) + # ( 1 ) (2. 59)

(1> 1
*a> = H - Ä< > (2. 60)
and the unit vectors of the responsible principal directions of Σ ( 1 ) can be expressed
by
e[l) = cos β tx — sin ß t2 (2. 61)

l
ei > = sin ßti + cos ß t2 (2. 62)
2. 5 THIRD ORDER GEOMETRIC PARAMETERS
In order to analyse the third order parameters of a generated surface, we consider

the relationships between the generating flank and the generated surface along the
instantaneous contact line at first. As long as the rotations of the surfaces are not
taken into account, the derivatives in the moving coordinates coincide with the corre-
sponding ones in the fixed coordinate system. From Fig. 2. 5 we know
Fig. 2. 5 The instantaneous contact line

and moving frame on the generating flank
ξ- = cos Θ = tx · ~e[f\ j - = sin Θ = tx · i ? \ (2. 63)

T h e n , from Eq. ( 1 . 2 ) , following parameters can be determined·
^ = p[n cos Θ + p\n sin 0, ^ = k[n cos 0, ^ = k\n sin 0 (2. 64)
From Eq. ( 1 . 1 ) , we have
d e[f > ^ώ'< / > ^ < / >

= +
d S dS 35
(2.65)
a5 " a5 e i
a5
an ( / )
a5 a5 ^1 as'2
From Eq. ( 1 . 38) it is known that the partial derivative of vaf) with respect to s will
be
<l/>
dv
= 5<^> X ?! (2.66)
ds
Partially derivate each argument of V n ( / ) with respect to 5, a new symmetric tensor

can be obtained, as follows:
dVn (/)
ds a5 a5 a! - /
σ)
l2p<f) 2ρ
(2.67)
ds ds
where
a£[(/)
k[fJ cos 0 + jfeft> sin 0 , ^ ~ = kfä cos 0 + *& } sin 0 (2. 68)
a5 a5
in which ^ ί ^ , k[ft2 , ^ίι* and £2(2* denote the partial derivatives of k[f) and k\f) with re-
spect to the are length of u- and ^-coordinate lines, respectively. T h e n , from Eq.
(2.42)
aP ( 1 / ) dvaf) „-c/>,-<i/) aVtt<^> ω«'>Χ^— (2.69)

ds
Denoting the geodetic curvature of the instantaneous contact line by G , we have
d2Rin dtx </) - (/)

3i2 = ^ds = Gi2 + i;;'»
eT + ole?
ef+JeV
Fig. 2. 6 An illustration of the moving frame on Σ ( / > before and

after the contact point moves a distance as along the contact line
Since Paf) · tl = 0 holds along the instantaneous contact line, its partial derivative
with respect to s will be equal to zero. Thus,
dPiin
• i 1 + G P ( 1 / ) · t2
ds
><!/>
Since tz = , the geodetic curvature of the instantaneous contact line can be
|F(i/>|
obtained as follows:
dPan
G = -
ds (2.70)
I pa/) I
Using the moving frame on Σ ( / * to denote the same geodetic curvature of the instan-
taneous contact line (see Fig. 2 . 6 ) » we have
d S d S
Therefore
M-«-H
T h e n , from Eqs. (2. 63) and (2. 6 4 ) ,
da)1 . 3θ 3ω2 _a0

—-jZ = — sin ΩΘ — , —5-
Z = cos 0 —
a 5 d S 3 S d S
y4 = 3Jflcose + 4K ,|i{, | 4 _ ?*£ sin θ + w ^ (2.72)

3 5Z 2 5 Z
3 5 3 Sl d S 3 S2
Subsequently, the second order partial derivative of the unit common normal with
respect to s can be obtained, as follows:
2~</> O ω3 O ω3 3 ωOpif) 3ω Opif)

( ό )
a* 2 a* 2 x
as 2 2
as ds ds ds ^
N o w , using the moving frame on Σ α ) to express the geodetic curvature of the in-
stantaneous contact line, we have
Π2
where ^ =/o<1) cos β + p?> sin β (2. 75)
From the structural equation
k[]\ = 2ri 1 ) Ä < 1 ) , *ft = 2rf 1) Ä <1) (2.76)
it is known
Ω\ _ k{\l cos /? + k£\ sin /?

(2.77)
as 2R(
3_ß = r _ kj\\ cos ß + kj\\ sin ß
o_ii = G _ ' » " » ^ τ . , , , . ^ (2i 7g)
3s ~ 2R
N o w , using the moving frame on Σ α > to express the second order partial derivative
of n ( / ) with respect to 5, the following equation is obtained:
^ = - J7 v - I f « ° - *>a>cos *(£ *>+*i u <- * » i

- A?> sin /? - ^ Ι έ{» + *ί»> sin /? n ( / > (2. 79)
where aflf = ( ^ , ^ ^ + ^;;> ^ ^ ^ ß _ s[a ß dß k{l>

öS o S
y ? = ( *£} cos /? + *<;> sin /?)sin ß + cos /? | £ *<» (2. 81)
Expanding Eq. (2. 79) according to the components of e[O and ^ 1 * > a set of equations
is obtained·
£<!> cos 2 β + 2k{)l cos 0 sin β + k£\ sin 2 β = · i™ + *«> G sin β

d J2
(2.82)
£<!> cos 2 β + 2ki]\ cos /? sin β + k?\ sin 2 β = - d

-^- · # > - jfe«> G cos /?
<7 5
(2.83)
However, these equations are not sufficient to determine the third order parameters
of Σ ( 1 ) > so the generating process has to be considered below. From Fig. 2. 3 we
know
£<n = #</> _ I
where L is a function of <ftn . Partially derivating this equation with respect to φσ)
gives
dRa>
— ^ ( 1 ) ; l< D _L *^nl
(2)
;<ΐ) _Lu„ a
7(i>X
vK# — a
^ ( / >
_ t (o ΧΛΛ
d<fn ~ 9<ρσ) ^ dcf ^ ^ ~ a^/> ^ (2.84)
where § | £ = ^ ?/> + ^ # > + ä<'> X *<'> (2. 85)
On the basis of the assumption that (/) is parallel to e[f) , the projection of the
moving speed of the contact point along e\n will be zero,
Ί = 0
Set ;</>
and substitute it into Eq. (2. 4 9 ) , we have
a)
- Wl/ä X L + L + ω α / ) X vif) - ä ( / ) X vaf)) = 0
T h u s the moving speed of the contact point along Σ ( / > can be obtained as follows
-</> . -
(2.86)
Z0n k[nvan · ~e[n + ω α / > · ~e\n
With this value, many vectors and parameters required for further calculation can be
determined:
P7?</> ^1 — P #(1) P^ ( / )
-
Ι ^ ^ ^ + ^Χ*«". Ü7T = ! f 7 T - £ (2.87)
^ Τ = ^ΓΤ - ^ - ί<"> · i i » , ^ = - ^ sin φ - ϊ < - · ί<»
(2.88)
where ψ = θ - β (2. 89)
further,
ω\ ,</>_
a ^ > ~ r i d^n' d(ffn~ l
3φσ)9 d<ff
a^/) <**!i ;</> 4- - ^ X - *</> 4- ;;</> v ;</>

a^7) d<pif) 3φ{η
i ;(/> _u ::</>
(/ v ;</> (2.91)
d<fff) ' d<ff7> *i + a > X ei
9n(/) _ iy > e {/) +
;</> 4- Λ <(/>
fl /> v n
X *</>
ap(/) a? (
a^1^ - a #(1) - a#(/)

(/)
V
dp = Ml/ 5«» x *«> + βι/ 5<» x f^7>
dp + ^ - 5 X ^dpτ τ (2.92)
Ά n^f > — / 3 7? a>

a q
7Τ = ϋ ·. 5 <
1/
1 . T*n\
- ( i i>.Χ Α <1 i ·
> + « 1/—5i<
ιx , I » Λ
n > Χ ,^7Τ L + 5</>| - Ml/5
3^ —"-'"
x L + L + 5«/> x 5</> X^ U - 5<'> X i ^ y( / (2. 93)

a^ a?
Partially derivating Eq. (2. 86) with respect to <pif) gives
dn (/) (1/) ~1
a^7> * ?
<!/)
+ *»·!£
a^> a^>
σ α/
ΐΛρ > ^7) >\ aî/)
l
^ \3 0η ^ ι
3 0η)^30η ~ruifa e
z
a ω1
k[nvan · i[in + ΰ α / ) · # >
f)\2
(a^>)
(2. 94)
Therefore, the second order partial derivative of the unit normal with respect to <ftf)
can be obtained from Eqs. (2. 90) and (2. 91) »
««</> dco1 </)
(2.95)
1
a ^ d(fff) ^ a x
a^(/)
If the generating flank is a circular cone» k[l) = k[\\ = 0» some equations presented
above can be greatly simplified. Equation (2. 86) will become
(2.96)
d<ff />
Equations (2. 90) will become
(2.97)
a φσ > a^ > )</>
a <ff
Equations (2. 91) will be
a
d<p(f) ~ * «i
d(pif) - a
* e
* (2.98)
an ( / )
ä(/) X n ( / )
a^:/)
Equation (2. 94) will become
aw1 ap (/) * + n
a^> a^/)[a^/> + wi/" ·*ι |
(a^>)2 5 . ^</>
(2.99)
Finally, Eq. ( 2 . 9 5 ) will be
(2.100)
(a? (/ />) )\ 2 a^-
Then consider the moving frame on Σ α ) . First,
Ω1 Ω\ Ω2
2 (2.101)
d(ff :/> d<p{ :/) » a^ > ~ * a^>
From Eq. (2. 88) » we have

aß 1 aZ 1 , ω1 . , 3ψ dvan -(1) - ( 1 / ) dejl)
( 5 y ^ = W ^ c o s 0 ~ ^ s i n 0 ^ ~ ^ 7 y "l v %
W
(2.102)
2 1 1 an
aß aZ . , S , 3ψ dv -(1) - (1/) dejl>
sin
Ί^ψτγ = - ^ψτγ * ~ γψη cos tpj^n - j^rv · «il> - * α / ) · ^ τ τ
(2.103)
where
3 z. Π2 Π3
d g d i
i _ i ;<i) i ''i -(/) i „ "(I) v Id) (o 1fU>)
a ^ ( / ) ~ 3φσ) 2
â^(/) +"ι/α Χ
*i (2.104;
3 ^<1> Π2 03
dg 2
2 —— * ;<D -U «</> + « , Λ α > V ^ a ) Γ? 1 0 Ό
w
9φ ~ σ)
9φ σ) X
^ d<fn + i/a x
*2
U.lUb;
O1 O2
A < 1 ) _ ^ _ _ _|_ A ( D _ Ü _
in which ^ = ^ 2Jt<1> ' * (2. 107)
If the moving frame on Σ ( 1 ) is used to express the second order partial derivative of
n ( / ) with respect to φσ),
a2n(/) _ _ dh\ -(1) _ go» -(1) _ _ß|_ ^ ί ^ _ _ß|_ affl

(a^/>)2 - (a^(/))2 €l (a^(/))2 *2 a^(/) a^(/) d^n a^(/)
(1
+ Wl/ä > X n<'> + uxfa™ X | ^ J (2.108)
where
_^__iÄa)_flL + Äa> _ * _ ) _ * _ + *<»_£*_ f2 11(n

(a^>) 2 ~ Γ 2 · ι 3 ^ > + * 2 , 2 a^>) a ^ > + * 2 o $*">)* «·"<»
Expanding the both sides of Eq. (2.108) with respect to the components leads to
dOj ΩΙ_ Ω\
Ορσ>)2 d(fff> 9φσ)
a2™</> Ω
(a^>) 2 €l + .W l / a— (Λ\ n—(f\
d<?n
o n -n\ ■*:
"
+ jWl/5(1> X n<'> + Wl/5
(1
> X | ^ i j . i[» (2. I l l )
aß* a; flf
(a^ / > ) 2 ^ a^'> a ^ / >
( a ^ > ) 2 *2 lf
d<?n
+ ( Wl/5(1> X « ( / ) + Wl/5
(1
> X | ^ J j · #> (2.112)
Substituting Eq. (2. 109) into Eq. (2.111),
rlaa^(/) ^ 1 2
' a^/)] a^> *2 d<fn d<fn
Al
(a^>) 2 (a^>) 2 ei
+ *"* n
a^/>
+ \uua™ X S ( / ) + Wl/5
(1
> X | ^ j · i«> (2. 113)
Substituting Eq. (2. 110) into Eq. (2.112),
2 2 1
1(1) ^ I JL<1> ^ | Ά I jL(l> ^ ^ Ι
2a (/) 2,2 /) /) l
* a?> ^ a^ ] a ^ ^ a? ( / ) a ^ >
2 2 3
3 Π Ρ Μ<^> Π
2 2 (/ 2 2 UlfCL n (/
(a^>) (a^ >) * a^ >
(1
+ ( W l / ^> X n<'> + Wl/ä > X | ^ J j · #> (2. 114)
Substituting Eqs. (2. 102), (2. 88) and (2.107) into Eq. (2. 113), and after simpli
fication, we have
+ α115)
W(T?*)' + w S^^ ΗτΡΪ - d>
where
dx= kp Ml/( <z<'>, # > , »<">) - ( /^

o ^ /) >
) 2
)2-^
cos I - ^ > sin 0 ( ^ >
a^/>»
a/> il 3
ZOO ·«{» + «1/
a^
3 n </> ((i)
1) .· *;a>
( 1) _ »*<» .· ;a>
(
+ a«>, 4- 1J . / 7 —— P
€
(2.116)
a^ + «I/* *2 0^/>)2 1
Substituting Eqs. ( 2 . 1 0 3 ) , (2. 88) and ( 2 . 1 0 7 ) into Eq. ( 2 . 1 1 4 ) , and after simpli-
fication, we have
/ Ω1 \2 Ωι Ω2 I Ω2 \2
uz 2
\d^n) ^ 2tl
d
' «*"» *""> + ( ^ T y sin <* - ^ cos φ ( ^
ITU/ 9ί α '> 03
3° «1/
a^/>
£ *;</> ;
2~</>
5 - i t f ? » · e i 0 - av 2 ^2 (2.118)
(a^>)
When the four linear equations (2. 8 2 ) , (2. 8 3 ) , (2. 115) and (2. 117) are used to-
gether, the partial derivatives of the principal curvatures of the tooth surface with
respect to the arc length of the lines of curvature can be obtained. Because of the
special structure of this set of linear equations, they can be easily reduced to
0 Ω1 J O 1 · » & *\ L«>
2
J^n cos 0 j^n sin β - j ^ cos 0 k{]>2
a ß2
+ sin2ß
\3Wicos2ß
c
«2,1 — l
τψ-ή -
sin 1(1)
^-[ä?7>)cos ß Ä
\τψϊ) l,2
2
+ J^n «n /*( ^ 7 > » " ß ~ JfH cos 0|*ft = c2
rhere
ß1 WLC»^ . o a V / >
"(1)1 d,cos2ß (2.119)
d<fff ds2
c2 = [ ^ 7 > J *?> G cos /? + ^ - · ϊ«> + <f2 sin2 /? (2. 120)
From which we have
(äf^) 2sin ^-(ä?H 2cos2/?

Ω2 I Ωι Ω2 \
C2 2
£(1> _
J^n^ß[j^n^ß- γψη cos /?]
*1,2 — (2.121)
2 cos sin
Ω2
ä^T) 0 (ä^T ß ~ Jfn cos /?!
1(1)
*2,1
ιψ-ή sin ß
[w*h^_
-\äwA { Cl
(2.122)
Δ
wher
2
τ^0Ο5βΡι (2.123)
2 Ω·
J^n sin /? Λ
in which
Pl =
JW>sln ß
~ JW~>cos ß (2.124)
sin2ß
P2 =
\W>) ~\äWy)cos2ß (2 125)
·
T h e n , by substituting the obtained values into Eqs. (2. 115) and ( 2 . 1 1 7 ) ,
L<1)
*1,1 rf _2^>^__^_^α>ί^_)2] / ß1
(2.126)
«i î'2a^(/> a ^/> Ä
*.i(a^/>) /
k a^ ,(/>
Jt(l> _ ß1 β1 Ω2 ß2
*2,2 — ( 2 ki)ldfff> a^/> (2.127)
a^ :/> a^:/>
Finally, from the structural equation, the geodetic curvatures of the lines of curva-
ture on Σ ( 1 ) can be determined·
jt(l>
(1) _ *1.2 *2,1
«" = 2£ ( 1 ) (2.128)
Pl
" 2Ra >'
The authors believe that this chapter is the most complicated one. Since many equa-
tions for both deduction and calculation are all presented in the same chapter, read-
ers may find it difficult to pick out those necessary for calculation and put into prac-
tice. Therefore, a numerical example is presented in this section to demonstrate the
real operation process.
The parameters of a pinion's concave side (drive side) are calculated in this example.
The parameters of the generating flank are given as follows:
<p? = 13°36', R = 151.1077 mm

Considering the coordinate system for machining process w h e r e : the origin is at the
machine centre, x axis directs upward, and z axis coincides with the rotating axis of
the cradle. In this system of coordinates, the vectors of the axes of generating flank
and gear blank a r e :
ασ) = - k
a)
a = 0. 98732 J - 0. 15878 k
and the position vectors of the reference point on both Σ ( / ) and Σ α > a r e :
£></> = - 40. 8461 i + 123. 2463 J + 11. 2736 k
Ra) = - 8. 0161 1 + 154. 3882 7 + 6 . 2655 k
From Fig. 2. 3
Z = 32. 8300 1 + 31.1419 J - 5. 0081 k
The machine has a modified-roll mechanism, without cutter-tilt mechanism. Both

the axes of Σ ( / > and Σ α ) are fixed ones. The angular velocity and the angular acce-
leration of Σσ)ζτε:
j j ü - = 0.16348, -^φγ2 = - 2. 04708, - 4
From which we have
ulf = 6.11686, ulf = 4. 68513, — 2 , ulf = 1. 07655, — 3
From Eq. ( 2 . 3 5 ) :
0, kin = 6.43224,- 3
*2,1 - 1. 00094, - 5
The unit vectors of the principal directions and the normal of Σ ( / ^ r e :
e[n = 0.13961 1 + 0.18921 7 + 0. 97196 k

'βγ> = - 0. 80468 ~i + 0. 59371 J
nin = - 0 . 57707 t - 0. 78211 7 + 0. 23514 k
From Eqs. (2. 41) , (2. 36) , (2. 37) and (2. 38) we have:
5<l/) = 6 . 03927 1 + 0. 02880 J

v{f) =123.2463? + 40.84617
va) =187. 7813 ι + 7. 7853 J + 48. 4114 k
an
v =64. 5350 ι - 33. 0608 7 + 48. 4114 k
From Eqs. (2. 42) and (2. 43) ,
pa/> = _ 1# 81299 7 + 0# 28989 7 - 3. 48505 k

t% = - 0. 46025 ? + 0. 07359 7 ~ 0. 88473 k
tx =- 0. 67466 7 + 0. 61877 7 + 0. 40244 k
From Eqs. (2. 51) and (2. 50) ,
qaf) = 3 3 . 3229 ι + 68.1439 J - 743. 9465 k

Si/=- 542.761
From Eqs. (2. 56) , (2. 57) and (2. 58) ,
ß =85.7976°
Ä = - 0.0165856
//<i) = - 0.0110780
Then from Eqs. (2. 59), (2. 60), (2. 61) and (2. 62), the second order parameters
of2 (1) can be obtained:
k[n = - 2 . 76636* - 2, k^ = 5. 50764* - 3

e[l) = 0 . 40958 ~i - 0. 02805 7 + 0. 91184 k
eP = - 0 . 70657 ϊ + 0. 62250 7 + 0 . 33652 k
Now , we calculate the third order parameters of Σ ( / ) · From Eqs. (2. 63) and (2.
64),
CO CO
— = 0.41405, ^ - = 0.91025
d S dS
co\ co\ co\

ττ = 1. 4165* - 3, -^ = 0, ^ - = 5. 8550* - 3
a S d S σ S
From Eq. (2. 65),
de\ (/)
= - 1.1398* - 3 7 + 8. 4097* - 4 7
ds
3*Υ>
ds
= - 3 . 5765* — 3 i — 4. 8473* - 3 7
9ησ>
ds = 4. 7114* - 3 1 - 3. 4762* - 3 7
From Eqs. (2. 66) and (2. 68) ,
at; (1/)
= 2. 4126 7 - 1. 9429* - 2 j + 4. 0744 £
ds
a*<</) = 0 , = - 4.1444* - 6
55 ds
FromEq. (2.67),
- 3. 4339* - 5 -1.3411*-5 0"

dVn </>
- 1.3411* - 5 3. 8483* - 5 0
ds
0 0 0.
From Eq. (2.69),

3P(1/) -
—z = - 1.1981* - 2 i + 5.1846* - 3 j + 2. 8453* - 2 k
aS
From Eqs. (2. 70) and (2. 71) ,
G = - 5. 7733* - 3 , f^ = - 7.1898* - 3 (rad)

d 5
FromEq. (2.72),
^ω1 /. Γ-..r o ^ω2

^ Τ2z = 6. 5445* - 3 , -r-^
-τ-ζ = - 2. 9769* - 3,
dS 55
3ω\ _ 9ω:
55 22 =" 0° , ' —
ds'i = — 2. 2921* - 5
T h e n , from Eq. ( 2 . 7 3 ) ,
d2nin
—JJT = 2. 4962* - 6 2 + 4.1989* - 5 j
FromEq. (2.96),
ω
τ> = - 69. 0149
FromEq. (2.87),
777 = jzm
d qH > d
= 113. 6113 ί + 27. 7875 j - 67. 0798 k
From Eqs. (2. 88) and (2. 89) ,
Ω1 Ω2
ψ =- 20. 2571°, ^ 7 7 = - 136. 2494, j-ρϊ = 25. 9922
From Eqs. (2. 97) and (2. 98).

>= o
a φσ> a φσ> a p(/
^~V) = 0.18921 i - 0.13961 >
dein
a?I( /n = 0. 59371 i + 0. 80468 j
an(/)
d(jff 7> = - 0. 78211 i + 0. 57707 j
From Eqs. (2. 92), (2. 93) and (2. 99),
aü(1/)
—jjj = - 404. 4748 i + 3. 3314 j - 685. 7585 k
aö (1/) -
y ^ 7 7 = - 2. 6189 ι - 405. 4351 j - 178. 7643 k
dw1
(a^>)2 174. 900
Then, from Eq. (2.100) we have :
( 0 7 7 ^ 2 = 0.57707 7 + 0.78211 j
FromEqs. (2.101), (2.116) and (2. 118),
j ^ = 3.76915, ^ > = 0.14316
dx = 26.3250, d2 = 23.8723
FromEqs. (2.119), (2.120) and (2. 123),
ci = 2. 81841, c2 = 23. 7590, Δ = - 3. 60448e + 8

Thus the partial derivatives of the principal curvatures of 2 (1) can be obtained from
Eqs. (2.121), (2.122), (2.126) and (2.127) j
k[\l = 1. 2727* - 3, ki\l = - 3. 7014* - 5

k[\\ = 1. 9050* - 3, k£l = - 2. 3595* - 5
Finally, from Eq. (2.128),
Pliy = - 3. 8367* - 2 ρίΏ = 1.1159* - 3
The results derived here have been used as known parameters for the analysis of con-
tact situations of a pair of hypoid gears, that has been presented in Chapter 1.
2.7 CONCLUSION
A general method for the analysis of a generated tooth surface up to the third-order
geometrical parameters at reference point is presented in this chapter. With the pa-
rameters obtained, not only can the analysis of the contact situations of a pair of
combined mismatched tooth surfaces up to the third-order contact be performed (see
Chapter 1), but also further investigations into both the rates of change of the con-
tact parameters of a gear pair under vertical and horizontal check and the sensitivity
of the contact performance of a gear pair to the misalignment. Further a fast re-
sponse can be expected. The numerical example demonstrates the process of opera-
tion. The results found from this example have been used as known parameters in
the example for calculating the contact situation of a pair of hypoid gears (see Chap-
ter 1). As the solutions found from the third-order contact analysis presented in the
last chapter compare well with those from TCA program, the validity of the algo-
rithm presented here has already been established.
3
Analysis of the Rates of Change of

Contact Situations of a Gear Pair
under Vertical (V) and Horizontal (H) Check
3.1 INTRODUCTION
The third order contact parameters of Gleason spiral bevel and hypoid gears can be
classified into two groups. The first group includes the rates of change of the second
order contact parameters of the gear pair with respect to the rotation angle of the
pinion <pa) or the arc length of the contact point path ( C P P ) sa) and s<2> on both the
pinion and gear tooth aurfaces when the gear pair is under theoretical mounting dis-
tances. These may b e , for example: the changing rate of the angular acceleration of
dV2)
the gear relative to the pinion ( . ( 1 ) . 2 with respect to the rotation angle of pinion,
dV2)
i. e. the higher order relative angular acceleration , ,^z ; the rates of change of the
directions of CPP with respect to their arc length, i. e. the geodetic curvatures of
CPP C ( 1 ) and G<2) ; and the changing rates of the length of the major axis of the in-
stantaneous contact ellipse with respect to the arc length of CPP on both surfaces
-y-<f) and -wfj . T h e second group involves the rates of change of the second order
contact parameters with respect to the distance s* of the centre point of the contact
pattern moving lengthwise along the gear face under V and H inspection (e. g. the
rates of change of the directions of CPP on the tooth surfaces, the angular accelera-
tion of the gear relative to the pinion, and the inclination and the length of the in-
stantaneous contact ellipse with respect to s* ) C n 3 . T h e first group of the third order
contact parameters have been analysed and discussed in detail in Chapter 1. T h e geo-
metrical parameters of tooth surfaces up to the third order, which are required for
the calculation process, can be worked out by means of the algorithm presented in
Chapter 2. This chapter will analyse the second group of third order contact parame-
ters and derive the required algorithm. Since these parameters are important for un-
derstanding the sensitivity of the contact performance to misalignments, they are
necessary in the evaluation of machine and tool setting scheme.
As in the earlier chapters in this book, all the formulae are presented in explicit
forms. Calculation examples and experimental results are also given at the end of
this chapter.
3. 2 T H E L O N G I T U D I N A L DIRECTION A N D GEODETIC C U R V A T U R E
O F L O N G I T U D I N A L LINE
In order to analyse the changing rates of the second order contact characteristics of a
gearing with respect to the moving distance s* of the centre point of the contact pat-
tern along the longitudinal line of the gear tooth surface Σ ( 2 ) > we have to define the
longitudinal line of tooth surface, and analyse its geometric properties at first. T h e
longitudinal line is defined as follows: suppose the reference point on gear flank Σ <2>
is M , see Fig. 3 . 1 . Through M we make a circular cone S G R which is parallel to the
root cone of the gear, termed as reference cone. T h e intersecting line formed by the
reference cone S G R and the tooth surface Σ ( 2 > is defined as the longitudinal line of
gear flank, and its arc length is denoted b y s * . The cone distance AGand the distance
bG between 2 G R and the root cone are determined by the required position of the ref-
erence point. Conversely, if the values of A G a n d 6 G a r e given, the position of the ref-
erence point is uniquely determined. As described in Chapter 6, when the contact
situations up to the second order are predicted, the position of the centre point of the
contact p a t t e r n , i. e. the reference point, is predetermined by giving the values of AG
V AND H CHECK 65
and bG
Suppose the unit normal of Σ ( 2 > at point M i s έ 3 , and the unit normal of E G R at the
same point is nGR. Since the longitudinal line is the intersecting line of the two sur-
faces, its tangent is perpendicular to the two normals (see Fig. 3. 1 ) . Thus the unit
vector of longitudinal direction can be expressed as
ε3 X nGi
(3.1)
e3 X nG
The unit vector of the profile direction will be
τχ = r 2 X e3 (3.2)
Use a = cos l(e3 · nGR) (3.3)
■ AG
\' f
^ V- M fcb
\
Κ>^Μ%Α 1
Fig. 3. 1 The reference cone of the gear
to denote the directed angle from ε3 to nGR (Fig. 3. 1) , and β and k the unit vector of
the principal normal and curvature of the longitudinal line at point M. Denoting di-
(2)
rected angle from e3 to ß by αγ , the normal curvatures of both Σ and Σ ο κ along r2
can be expressed as
k^ =k 0 . e3 = kcosa, (3.4)
kG* =k β· nG* = k cos (a - a,) (3. 5)
On the other hand, the values of k™ and kG* can be obtained respectively as follows :
2 )
4 = - r2 · (? 2 · V n ( 2 ) ) (3.6)
G
kcR==\ r2 X l \
where 2G is the unit vector of the generatrix of the reference cone which passes
through point M , Γκ is the root angle of the gear, and Vw ( 2 ) is the curvature tensor
of gear flank at M , which is the sum of two diads, can be expressed in the form
V n ( 2 ) = - k™ e\ e\ - *<2> i% e2
here e\ and e2 are the unit vectors of principal directions of Σ ( 2 > at point M , k[2) and
k{22) are the corresponding principal curvatures.
Then from Eqs. (3. 4) and (3. 5) we have
,GR ,<2> , ·
kr — k-x cos a — k sin αλ sin a
Using it together with Eq. (3. 4) leads to
GR
L L<2)
kr — k\ cos a
tan a 2
i = ,(2> .' (3. 8)
kr sm a
Since the geodetic curvature of the longitudinal line on the gear flank can be ex-
pressed in the form
V AND H CHECK 67
GL = k sin ax (3.9)
the following formula can be obtained from Eqs. ( 3 . 4) , ( 3 . 8) and ( 3 . 9) «
kg* - y^2)cos a
GL = (3.10)
sin a
3. 3 T H E R A T E S O F M O V E M E N T IN V AND H DIRECTIONS
The situation of pinion and gear tooth surfaces Σ α > and Σ ( 2 > in contact at the refer-
ence point M is illustrated Fig. 1. 1, where α α ) and <2<2) denote the unit vectors of the
rotating axes of the pinion and gear. The angles of rotation are respectively denoted
by <pa) and 9?<2). Ra) and R{2) denote the position vectors from the fixed points on both
axes to point M , and L is the vector from the point fixed to aa) to the point fixed to
ä(2>.
-a'(-)
Fig. 3. 2 The relative move- Fig. 3. 3 The movement of the

ment between the axes centre of contact
During the so-called V and H inspection, the axis of the gear should be moved some
distances dV and dH in vertical and horizontal direction from its theoretical mounting
position, as illustrated in Fig. 3. 2. In order to keep the backlash of the gearing not
to be changed drastically, the relative movement between their axes in the horizontal
plane is along the generatrix of the pitch cone of the pinion. After V and H move-
m e n t , the centre point of contact pattern should be still in the middle of full working
profile and the gearing can still transmit movement smoothly and continuously.
T h u s the movement of the contact centre should be along the longitudinal line of the
gear flank. A l s o , the instantaneous transmission ratio at the centre of contact should
be kept unchanged after the movements, this being of the theoretical value un, i. e.
the ratio of pinion tooth number to gear tooth munber. We shall discuss below the
method to determine the ratios of dV and d H to the differential arc length ds* of the
moving distance of the contact centre along the longitudinal line under the condition
that above mentioned situations are implemented.
Under the theoretical mounting distance, the centre of the contact pattern of the
gear flank is at the reference point M. The unit vectors of the principal directions of
gear flank at point M a r e denoted by ^ and e 2 , respectively, with the supposition that
e!,e 2 and i 3 from a right-handed system. When the contact point moves along the gear
flank, the frame composed by the three vectors moves like a rigid body in line with
the movement of the contact point. This frame is termed here the moving frame of
the gear flank. Similarly, the unit vectors of the principal d i r e c t i o n ^ , £ 2 and normal
line e% of the pinion flank also compose a right-handed system; this is named as the
moving frame of the pinion flank. In the coordinate systems rigidly connected respec-
tively to the pinion and gear, the derivatives of the frames with respect to s* can be
expressed as follows:
d el
2 + (3.11)
ds' ds* ' ds* '3
de2
ds* ds' βι +
* 2 ds* 6* (3.12)
de3
ds* * l ds* βι
* 2 ds* 6z (3.13)
&-&*+«·&*
£--&-*+«&-·.
V AND H CHECK 69
_ £l
d5* kl
ds* * 2 ds" £l (3,16)
where
d^ = ^ V + rf>
dT · 5r = ^ 3r + ^ a r (3 17)
·
Here £ ί ° , £ 2 ° , î2> and £22> denote the principal curvatures of pinion and gear flanks,
ΡιΏ» /°21)> /°i2> a n d /°22> the geodetic curvatures of the curvature lines of both surfaces;
ω' and Ω* deonte the projections of differential moving distances of the contact point
on the frames. In the fixed coordinates,
&-£ + *»*«£
& -a? +«"> x MS?

From Fig. 3. 3 it is known that if the centre of contact moves a distance as* in the
longitudinal direction r 2 ,
Ω1 Ω2
-^τ = Γ 2 , · ε 1 , — = r2, · ε 2 (3.24)
Thus the changing rate of ε3 in the moving coordinates can be obtained from Eq. (3.
16). During the V and H movement, the rates of change of the position vectors of
the centre of contact pattern on both surfaces in the fixed coordinate system can be
expressed as follows:
ARW ω1 - ω2 - - - Aafu
dR
d s - = r 2 + a<2> X R™ ^ τ - ( 3 . 26)
Using ?! and ? 2 to denote unit vectors of the relative movements between the axes in
vertical and horizontal directions, following equations can be obtained from Figs. 1.
l a n d 3.2:
dL^ dU Ky -i* . UJT2

AH ~, * ,n Λ„ Ν
ds*7 = ds*
X T *?il ^+ iasr r sec / ? 2 ( 3 . 27)
dfl(1> _ dR™ dL ,0 . . .
+ C3 28J>
ds* ~ ds* ds* '
where / is the pitch angle of the pinion. N o w , we shall set to determining six un-
. S1 Z2 dp (1) dp (2) dV a n d. dH _ , ,
knowns -j-7 , j — ^ , -r-7" > i - r » T"r ΤΎ · In order to make the treatment easi-
ds ds ds ds ds ds
e r , let
i . = f i X ft (3.29)
and the projection of d L o n ? 3 will be zero. Substituting Eqs. ( 3 . 25) , (3. 26) and ( 3 .
27) i n t o E q . (3.28),
ω',2 _ - H">
- ex + T-T ^2 + α α> vX J?<D
R
ds* '* ' ds* *2 ' " <i) ~ *v ds*
+ a5<2) X K
= Ϊr 2, -h ϊ? <2) ^d r + d—r fri£ +
-h -h d—
r £ 2£ sec
s e c /r
Then making a scalar product with £ 3 , we have
I .~t*L±i . ~ξ *L + ( ä 5 e Λ 4 2 ^ _ , - (2) ~(2) Ί aV^ _ - τ

1 3 3 3 3 2 3
ds* ds* ds* ^ s * ^ ~~
which can be written in the form:

V AND H CHECK 71
(3 30)
*»dr + b"dF + b»ll· + b«ll· - *» ·
where
bn = ii · f 8 » *u = *2 · fa. &i3 = ( a ( 1 ) . * ( 1 > . £3) ,

*i4 = - ( ä ( 2 ) , # ( 2 ) > £3) · ft» = r, · f, ( 3 . 31)
After V and H movement, the two surfaces must have the same unit normal at the
new contact point, i.e. e3 = e3 should be held, therefore
de 3 d£3
( 3 3 2 )
d^ = d^ ·
Substituting Eqs. ( 3 . 20) and ( 3 . 23) into above equation, we have
kl
as* 6l kz
as* *2 + a X 6z
as* ~ as* + a X
*3 d s * d**
Making scalar products respectively with ex and ez , following equations can be ob-
tained ·
+ a
- «"äF ·* 2 dr" - * #e
> dp" = dv · *
Ζ,(Ι) ^ 2 "(I) - <¥n . "(2) " <¥2> d

«3
2 x
d5* Ms* ds* ds*
which can be written in the form.
21
ds7" "aV~ "aV~ =
S2 d<p(1) d<p<2)
**ar +* * = - *" a ? - - *35
33 + (3 34)
·
where
-<2) - i. d e3 -
hi = — ^ίη» ^23 = tf(1) * *2> #24 = — a m · έ? 2 , £25 = j p r · *i (3.35)
A — £ u —
t?32 — ^2 , c/33 — αα> · «i, *3« = <*(2> · «1. * 35 = ^ r · e2 (3. 36)
In order that the instantaneous transmission ratio at the centre point of contact of the
theoretical value un can be guaranteed after V and H movement» the equation
(3.37)
should be valid at new centre point of contact pattern. Therefore»
de.
äil\RM + ds· ^-ds',it+âs· ( e « > , Ä " > , ί,)
= «2ΐ (3. 38)
5«,,^ + « ^ , . ^ + ^ . ) <*».*<*>.<.>
Neglecting the terms containing (as*)2 and after simplification, this equation be-
comes
,7(1) — ~P I _ L I ^(i> j?a> dem3 d#<2) - \ ~(2) E>(2) £fi

d* dS< > 5ff2 c _L I ^(2) D(2) r i «21
(3.39)
Suppose the angular velocity of the pinion is equal to 1, the relative velocity between
the surfaces at the reference point will be
t,«» = u2l a<2) X # (2> - 5(1> X Ra) (3. 40)
Taking e3 = e3 and -r-4 = τ-f- into account, Eq. (3. 39) becomes
V AND H CHECK 73
- (5<2> x i,) · (S a > x Ä(1)) ^
which can be w r i t t e n as
Z1 ω2 d^° d<z*2)
where
ft« = 5 (1) · € 2 , ft42 = - 5 (1) · il9 bi3 = (i (1> X ~eO · Ü (1) X * ( 1 ) ) ,
d e3
£44 = - (*«> X ί 8 ) · (α(1) X /*«>), 645 = (a< 2 \ € 3 ,r 2 ) - t;<21> · ^
(3.42)
Using Eqs. (3. 30), (3. 33), (3. 34) and (3. 41) together, the moving rates of the
centre point of contact pattern on the pinion flank - p - and 1-7 » and the additional
dcP> d<t2)
rotating rates of the pinion and gear -r-7- and -j-7- can be obtained. Substituting the
results into Eqs. (3. 25) and (3. 26), the rates of change of the position vectors of
dRa) dRi2>
the centre point of contact , # and , , can be determined. Then, from Eq. (3.
28),
dZ d# (1) dfl(2)
(3.43)
as* ds* ds*
Finally, the displacement rates between the gear axes in V and H directions can be
determined by
(3.44)
dH
— .£2coS7 (3.45)
ds*
3. 4 THE RATES OF CHANGE OF THE SECOND ORDER CONTACT

PARAMETERS
The second order contact parameters of a pair of spiral bevel and hypoid gears in-
clude the direction angle of CPP on both the pinion and gear flanks 0(1) and 0(2> (Fig.
3. 4) > the angular acceleration of the gear relative to the pinion dy 2) 2 , the inclina-
(d^) '
tion λ<2) , and the lengths of minor and major axes llf l2 of instantaneous contact el-
ds(1) d$<2)
and
lipse, and the moving speeds of the contact point on the surfaces Τ~ΤΪ> Λ ΛΒ·
CpponZtn
Fig. 3. 4 Some second order contact parameters of a gear pair
The calculation formulae of these parameters have been presented in Chapter 1. Here
we will discuss the changing rates of them during V and H movement process. How-
ever» the first step is to discuss the restricting conditions for ensuring a continuous
transmission at the new contact centre and determine some basic parameters.
dRa) dRi2}
In order that , , n = , , n is still valid for the new contact point after V and H
movement, the equation
V AND H CHECK 75
€l + 6z + a X <1>V
R1J?<1> = SL-
6 l +Ϊ. -Ux) e2 +c.a<2
J*— 4- X V l?<2>n ^L
n™Α<2>
άφα) άφα) X
~ d^l> d^ d^
will become
+^+^)-·](^&*·) +ϊ, " χ (*" + ^"·)

r ß1 , d I Ω1 \ , .«,/- . de\ „\
(3.46)
Taking into account ds* -»- 0 , the terms containing (ds*) 2 may be neglected. Then
compare it with the original one, this equation can be reduced to
d 1 d d
/ <"' \~ Λ · J ^ *i J · i / <*»M- , ,
T ü ids +
d7 ld7 r +W& dF\Wr
+ _^_ ^ ds* ++ 5o> xx ^
+ dj
5 .
d^> ds* ds*
d I A M - . . , ß l de! . d / Λ2 \ - . .
= T n idi + Tds +
d7 ld7 r d7^d7 ά^\ά^Γ
Expanding it according to the components of tj and e2. we get two linear equations:
, d ( 5 M , . , d / S2
d5*|d^l>/ r
d5"\d^l>
,^_d^ ^.d^j I dK«>
d ^ 0 ds* ^ d<ftl> ds' | l
^ Γ ' ds' '
d I Ω1 \ . Ω2 de, - . f_(t) dtf<2> -\
, d / S1 \ , , d / S2 \
+
ωd«!+ , Z2 de 2\ - f-a (1) dfl(1) ,ez
ld^5r d^d5:l*e2 +
l (1>r
dr '
d / ß 2 \ , ß 1 dii - . f-(2) die>(2)
(1> #e + α<2>Γ
d5*id9 / ' d ^ d r * Ι άν 'εήΗη
where ψ is the directed angle from ex to ex . These two equations can be written in the
form·
+ Cn + Cl3
Cn
drUfH ds'w») drUfH " Cl5 C3 47)
*
Cn
dv(diH + Cn
ov(diH + Cu
drloy^) = C25 a48)
where
cn = — cos ψ9 cl2 = — sin ψ9 cu = 1,
Cis ei +
~id^> ds* + d^> d5* I r ' d** , e i i
ß2 d£2 - Ι-ω dÄ<2> -1 /o JAN
T,ei
-d^d7 ~r *17^'ει)Μ21' (3 49)
·
c21 = sin 0, c22 = — cos 0, cu = 1
» \w d^ w d^) ·e* + r ·υ
c =/ S1 d^ , + ω2 de2\ - . / - a ) dR
» Λ.« » 2
c
ß1 d^ - / dtf<2) - \ ,n χ
# e2
~ αΤ^ d^ ~ r '~d7^' e2 r 21 ' ( 50)
After V and H movement, another condition for the gearing performing a continuous
transmission , , n = -7—^ will become
V AND H CHECK 77
ω1 dl ωχ \, ,
ix + £ *'
*" + d i ^ )[d7* + dr(d7*r Jr i + 5 ^ * )

d*3
\ d5
/ d£i2) \ fl1 , d ( ß* \ .
d** *+£*·:
d&2) fl2 , JLlJ*_xA . - i de2 #
ds* l>
d^ "*" d s * U p (1)
'
(2) ^ d s . ) ddy>^(2)
+ a X [ e, + (3.51)
dâ)
where
di* ~ "'ds* ^ *" 2 di*

(3.52)
dkj Ω1 ,ß2
— = ii*>— μ i<* (3.53)
In the same way as for Eq. (3. 46)» Eq. (3. 51) can be simpified to
_ .„>_»!_ d e i . . . _ .«>_d_ d£in

*i : df*» d*· *i x d s - U ^ r " K1
d i * "0 d ^ 1 ) C l
d ( ω2 dkl» , . ~ -
*2 d α ί 2 1 fli Ci!
^ ^1 »> Η
dj*
( · * ds'ld^
He· Lw»> de*♦ d 5
d^1>ß2
+ 5(1> x ^% dj«
ds
= _ £<2>-ίΐ- ifL
■1 J,·
A · _ i«>
«I> d ( ß l L · " d
^ " A · ß l
-
e i _ d 5
d^dsTds - ^ d p - l d ^ r dp- dê>
** d f ^ d » * 0 5 ** c b ' U f H e2
dr di
d**» e2
Expanding it according to the components of e1 and ε2 , other two linear equations are
obtained:
*ld^>di* £l
*l C0
"*d,*UfH COSsi
di*d^> *2 d^>(b· 6l
*2 8m,p
d5*U^ l > ) smsi
d5' d ^ 1 ) + r 'd5',ei)
*2 d^1» ds* 6l Ä1
dj'U^»/ di* d^" +
r ' d^> di*' εη
,α> ω1 d«! - . d [J? \ . dk[n Zl ω2 de2 -

~ k"w> dF'e> +
** sin *Mw>) + sin
* d ^ d ^ - *2 d7* a ^ **2
-«»COS*—(—) - C O S < * ^ — 4- (S«> ^ i il
*2 cos
* d»*ld?H cos
* di* df*»> + r ' d i - ' e2|
2
*' dql·» ds" *2 d s ' U f H di* d^> +
Γ 'd^^dj·'62)
d I Z1 \ d I Z* | . d / Ω1 1
C31 + β + = c (3 54)
δτη dTÎ ' *7η d7^) '»δτη d7*j * ·
d 2
C 4 1Ai_^LI +.c < , 7/
n +\c _L T d / I ß
*>* T =i c 5 (3 55)
di-UH d7 la? ) "d7 |d7 | < ·
where
cn = *{° cos 4ft, <r32 = *£» sin ψ, cn = — *{2>
5
~ d?~ d ^ + *2 dT17 d r * e ' ~ c o s * Ί^ d^ ~ ^ d?" * e ·
. , d*2D S2 .... 2? de2 - / - „ „ de3 - \
cti = — *{" sin φ, ca = k(2n cos ψ, ctt =— *|2>,
_ d*<2> ß 2 fl» di, - d*i» 5» » dix -

c
« - d?~ d ^ + *{ W> dF 'e2 + Sln
* ST W> ~ * i > dr" **2
n
# d*i S2 .... S2 de2 - /_,„. d'e3 -\
~ cos φάίν W> ~ *«"d?n d7^ *e2 - r m > ' d F ' e2 ' (3 57)
·
V AND H CHECK 79
and
ω<21> = w21ä<2> - ä (1) (3.58)
From a set of linear equations of Eqs. ( 3 . 47) » ( 3 . 48) > ( 3 . 54) and ( 3 . 55) , the val-
ues of
dFi d^) 'dr (diH 'drl dTÎand dr 1 w)can be determined · Tt should
be pointed out that although the contact point can be determined by parameters s*
and <pa> 9 they cannot compose Gauss coordinates of a tooth surface, and therefore
the order of differentiation cannot be changed.
Now the rates of change of the second order contact parameters with respect to the
arc length of the longitudinal line of gear flank 5* will be discussed below. The origin
of the formulae of these second order contact parameters can be found in Chapter 1.
The directed angle from the tangent of CPP on gear flank tG to the principal direction
εχ can be found as fllows, see Fig. 3. 4:
fle, t _, α 5 9 )
- » (^/^)
Differentiating with respect to s* leads to
Ω1 _d_i JJM _ ]&_ _d_/ ]V_

d ^ n as* 1 c k W d ^ l ) as* \ dc?(1)
d(9(2)
(3.60)
as* ds<
whe
d5<2> // ß1 W / Ω2 \1
= (3 β1)
ayr> vld^) + 1 ™ ·
is the speed at which the contact point moves on the gear flank (the angular speed of
the pinion is supposed to be unity). From Fig. 3. 4 it is known that the directed an-
gle from Γχ to tG (the angle from the direction of the profile of the gear tooth surface
to the direction of CPP on gear flank) is
υ = 0<2> _ c o s " 1 ^ · r x ) (3. 62)
Fig. 3.5
Figure 3. 5 illustates the situations of the CPP» profile direction and principal direc-
tions of the flank at the contact point before and after the centre point of contact
moves a distance as* along the longitudinal line of the tooth surface. Differentiating
Eq. (3. 62) with respect to s* in the moving coordinates connected to the gear» the
rate of change of the direction of CPP on the gear flank with respect to s* is ob-
tained :
4
as* ~ as* ^ " äs*
(3.63)
The influence of this parameter on the contact pattern during the V and H check is il-
lustrated in Fig. 3. 6.
From Eqs. (1. 1) and (1. 5) it is known

V AND H CHECK 81
Fig. 3.6
dR <1> V /?<!> (3. 64)

άφα) ~ d<pil) €l +
dp (1) €l + α<1> Χ R
dg 1ω ωΖ
3 _ _ Ld) ~ _ IL _a a)_d_/_S_n- _ *«>_»_ 4*

ds'\win Ld5* d ^ l > + Ä 1 d i ' U ^ / J 1 l
d^di*
_ rd*£ _»_ u_d_/ _ S M -I _ _»_ dj
Lds* d^1» ^ * 2 di*l<¥ l ) jJ 2
d^° di Q5
(3.67)
When the reference point M i s in contact, the angular acceleration of the gear relative
to the pinion can be expressed as:
- (21) d # a ) - \ , - (my
21) de3
" '- —Try»
d^ 1 ^3 + v · d^>
d> ( 2 ) _
(3. 68)
(dp a1 )) )Λ 2
(5(2>,€3,^2>)
Thus the rate of change of the instantaneous angular acceleration with respect to s*
can be obtained by differentiating above equation with respect to s * :
d# ( 1 ) dR™ d^3_
ö(2i).9 + t;<21> ·
+
TXZU
as d^n e% ' d p a ) ' d5*
_d de3 d#a) de3 dJR<2> de3

as' df*l> • as* 9
df*» + w21 9
ds* 9 d^>
(2)
dV dtf(2)
2)
+ (d^>) 2
[ * as* + 5<2\ £ ( 2 \
de3
dp a>
_d_ dV
as* (dp ( 1 ) ) 2
(a< 2 >,e 3 ,* ( 2 ) )
(3.69)
The influence of this parameter on the transmission performance of the gear pair dur-
ing the V and H check is illustrated in Fig. 3. 7.
The directed angle ψ from βλ to lx is ψ = c o s _ 1 O i · ej) . During V and H movement,

the changing rate of ψ is
dtp ^ flj
ds* ds* ds*
(3.70)
where
ds' - ds' + U e
*ds'
•L _ * +5 « . 3
^ (3.71)
ds* ds* ds*
are absolute turning rates of moving frames in the fixed coordinate system.
The directed angle from ex to the first principal direction of the difference surface tx
(see Fig. 3. 4) is:
V AND H CHECK 83
Φ"
Gear Lag
Fig. 3.7
1 _, - fl(2) sin 2ψ
*?> 2 a>
Ä - R™ cos 2)2 - Αα>Λ<2> cos 2 Λ - sin 2^
d*j2) _ dk^ dkl1

/?< -R<
di* ds* ds" ds'
di*
(3.74)
4 [ ( £ a > ) 2 + 0? <2) ) 2 - 2Äa>ß<2>cos 2ψ]
The directed angle from ελ to tx (see Fig. 3. 4) is
A<2> = A<'> - φ (3.75)
Thus the rate of change of λ<2> with respect to s * is

dA<2) = dA<" άψ
as* as* as*
(3.76)
Therefore, the changing rate of the angle κ between the major axis of the instanta-
neous contact field t2 (the second principal direction of the difference surface) and the
longitudinal line with respect to s* will be (see Fig. 3. 8)
άκ _ dA^2> ΩΙ
dr ~ G L
as* as*
(3.77)
£*+<>/£*
Fig. 3.8
The influence of this parameter on the TCA resuls is illustrated in Fig. 3. 9. Since
the instantaneous contact field moves continuously across the tooth surface under
running test, the influence of this parameter is not easy to be noticed from the con-
tact pattern.
From Euler's formula it is known that the principal curvatures of the difference sur-
face are:
£<2i> = k™ cos 2 A<2> + k™ sin 2 λ<2> - £<!> cos 2 A«> - k?> sin 2 A<» (3. 78)
£<21) = k[» sin 2 A<2> + k™ cos 2 λ<2> - *«> sin 2 A«> - *«> cos 2 A«> (3. 79)
V AND H CHECK 85
Fig. 3.9
Differentiating the above with respect to s* ,
rU<21) H£ < 2 ) ..^ !

U / gl U
A<2> ro
C
n2 1(1) _ *2 <,; n2 3(1)
as* ~ ds*
W
° "* ' ds* d5* °S * as* Sm
*
+ 2# ( 1 > sin 2ψ ^ τ - 2Ri2) sin 2A<f> ^ - (3. 80)
21) (2) 2> 0

Η£<
Q 2
d£,
Q/g
d£$
Q
difei
Q/g
Hjfe
Q/g
* — l « : n 2 3(2) I *2 2 1(2) _ l :ς η 2 1(1) _ 2 2 3(1)
Sm + C S0 Sm CS
ds* ~ ds* ^ as* ^ d** *' as* ° ^
2 * ( 2 ) s i n 2A<2> ^ 2# (1> sin 2AJ» ^ r (3.81)

* as * ds
surfaces and the load is fairly light so that the elastic deformations of the teeth can
be neglected, the area where the distance between the surfaces is less than the thick-
ness of the marking compound δ can be regarded as the instantaneous contact spot.
This spot can be taken as an ellipse and the lengths of the principal axes can be found
as follows:
/.=
8* (3.82)
h V*i 21)
Fig. 3.10
Differentiating with respect to s*, the changing rates to them can be obtained as fol-
lows·
d/! 1 h dk[2n d/2 1 /, dk?»

(3.83)
as* 2 *{ M > di* ' di* ~ 2 k?» dj*
The influence of -τ~τ on the TCA results is illustrated in Fig. 3.10.
3. 5 EXAMPLE CALCULATION AND EXPERIMENTAL RESULTS
The rates of change of the second-order contact parameters of both sides of a pair of
hypoid gears are calculated to illustrate the analytical method presented in this chap-
ter. The results from TCA program and experiment are also given to make compar-
isons. The basic parameters of the gear pair have been presented in Chapter 1.
V AND H CHECK 87
The parameters at the reference point on the concave side (drive side) of the pinion
tooth are as follows:
Ra} = 5 . 80467 i + 151. 43496 ~j - 31.19278 I

ex = - 0. 472468 1 - 0.172474 7 ~ 0. 864307 k
*2 = 0 . 674001 1 + 0. 561174 J - 0. 480422 k
k[l> = - 0 . 0276636 k{2u = 0. 00550764
k{\\ = 1 . 90500e - 3 k[\l = 1. 27269* - 3
Wl = - 3 . 70143* - 5 k£l = - 2 . 35951* - 5
The parameters at the reference point on the convex side (drive side) of the gear
Ri2) = 4 0 . 80467 1 + 124. 80318 J - 31. 63147 k

ex = 0 . 823105 ~i + 0. 558167 7 + 0 . 1 0 4 6 3 1 k
e2 = - 0. 001597 1 - 0.181970 7 + 0. 983303 k
2)
k[ = 0 . 00682051 k\z) = 0. 00381927
k?X = - 7 . 00617* - 6 k?\ = - 7. 55212* - 6
k?\ = 1 . 25615* - 5 kgl = 1. 65271* - 4
The second order contact parameters are listed below :
dV2)
υ = 0°, l2 = 17. 6571mm, κ = 17. 9248% (dJ1))2 = - 0.0004 ,
ds (1) ds (2)
τ-<ϊ> = 22.1750 mm/rad , -τ-^y = 10. 5240 mm/rad
The rates of movement between the axes in V and H directions to ensure that the
centre of the contact pattern moves along the longitudinal line of the gear tooth are
given by:
j^r = - 0. 042053, - ^ = 0. 061606
The rates of change of the second order contact parameters with respect to 5* are
thus:
άυ d/2
1-7 = 0. 873327mm , —L = _ 9. 4 9 8 5 e _ 3 ,
as ds*
άκ Λ, d [ dV2)
^ = 0. 0798327mm , = 1. 731&? — 5 / r a d / m m
W [ j ^ t ]
As a comparison, the results from T C A program are given below. Before V and H
movement, the contact parameters are listed in Table 3. 1 as follows:
Table 3. 1 Contact Parameters at the Reference Point

Φ» -30° -20° -10° 0° 10° 20° 30°
X -0.09320 -0.03031 -0.00455 0 -0.00220 -0.02337 -0.08643
Y -5.29307 -3.57301 -1.81070 0 1.86450 3.78694 5. 76964
h 17.5595 17. 6028 17.6364 17.6571 17.6623 17.6508 17. 6228

K 14. 966° 15.827° 16. 809° 17. 925° 19. 186° 20. 597° 22.160°
Αφ™ 11.089" 4. 946" 1.245" 0 1. 274" 5.181" 11.920"
If the both moving distances of the centre point of contact to the toe and in the heel
are 1 m m , the required movements in V and H directions from T C A a r e :
To the t o e : V = 0 . 041656 m m , H = —0. 061080 mm

In the heel: V = —0. 042458 m m , H = 0. 062146 mm
After V and H movements, the contact parameters are illustrated^ respectively in Ta-
bles 3. 2 and 3. 3 :
Table 3. 2 Contact Parameters at the Toe

Ψ» -30° -20° -10° 0° 10° 20° 30°
X -0.80917 -0.90735 -0.96587 -1 -1.02796 -1.07053 -1.15020
Y -5.23129 -3.53067 -1.78896 0 1.84167 3.74032 5.69850
h 17.5627 17. 6075 17. 6429 17. 6659 17.6739 17.6651 17.6369
K 14. 930° 15.779° 16. 747° 17.846° 19. 087° 20. 477° 22.017°
A<p™ 11.596" 5. 168" 1. 300" 0 1. 327" 5. 389" 12. 360"
V AND H CHECK 89
Table 3. 3 Contact Parameters in the Heel
Φ» -30° -20° -10° 0° 10° 20° 30°
X 0. 99382 0.96691 0. 97449 1 1.02396 1.02446 1.02181
Y -5.35571 -3.61591 -1.83274 0 1. 88766 3.83423 5.84181
h 17.5551 17.5971 17.6287 17. 6469 17.6495 17.6353 17. 6047
K 15. 002° 15.875° 16.872° 18. 005° 19. 286° 20. 720° 22. 306°
Δφ™ 10. 580" 4. 722" 1. 189" 0 1. 220" 4. 970" 11.440"
If the moving distances of the ccentre point of contact to the toe and in the heel are e-
qual to 10 m m , the required moving distances in V and H directions from T C A are as
follows :
Ψ» -30° -20° -10° 0° 10° 20° 30°
X -9.00092 -9.38940 -9.71907 -10 -10.2449 -10.4693 -10.6915
Y -4.70915 -3.17326 -1.60555 0 1.64928 3.34758 5.09918
h 17.5336 17.5865 17.6356 17. 6776 17.7089 17.7264 17. 7275
K 14. 633° 15.385° 16.233° 17.191° 18. 270° 19.481° 20. 830°
Δφ™ 15. 828" 7.049" 1. 768" 0 1. 787" 7. 203" 16.369"
T o the t o e : V = 0. 38380 m m , H = — 0 . 56860 m m

In the h e e l : V = — 0.46473 m m , H = 0. 67674 mm
After V and H m o v e m e n t s , the contact parameters are listed in Tables 3. 4 and 3. 5:

<ff» -30° -20° -10° 0° 10° 20° 30°
X 9.01123 9.34186 9.67910 10 10.27908 10.48957 10.60513
Y -5.96004 -4.03079 -2.04616 0 2.11235 4.29330 6. 54254
h 17.4739 17.4998 17.5115 17. 5070 17.4858 17.4492 17. 4003
K 15.339° 16. 330° 17.473° 18. 780° 20. 259° 21.908° 23.719°
Δφ™ 5. 555" 2.516" 0. 647" 0 0. 701" 2. 955" 7. 049"
T h e parameters at the reference point on the convex side (reverse side) of the pinion
JR(1) = - 9 . 95013 i + 155. 52460 ~j - 31.19278 k

~ex=-0. 462875 1 + 0.150026 7 + 0 . 873635 k
e2 = 0 . 578667 1 + 0. 797734 7 + 0 . 1 6 9 6 0 1 k
k[» = - 0. 0350131 W = - 0. 00509814
k{]\ = - 1. 30089* - 3 k[)\ = - 7.10697* - 4
k£\ = 4 . 90912* - 5 k£\ = 3. 61144* - 5
The parameters at the reference point on the concave side (reverse side) of the gear
# < 2 ) = 2 5 . 04987 ι + 128. 89282 7 ~ 31. 63147 k

ϊι = 0 . 702075 ι + 0. 698326 7 + 0.139401 k
e2 = 0 . 237066 ι - 0. 413798 7 ~ 0. 878960 k
2
k[ > = - 0. 00580856 k(22) = 0. 00512128
k[2\ = 2 . 45029* - 6 k[*\ = - 2 . 78628* - 5
*2?i = - 6 . 30456* - 5 k?\ = 2. 61933* - 4
The second-order contact parameters are listed below :
dV2) =
y =0°, Z2 = 17. 9480 m m , κ = 20. 6035°, (dTny 0. 0004 ,
ds(1> d5<2>
j-ΤΠ = 21. 0733 m m / r a d , - r - ^ = 8. 77601 m m / r a d
The rates of movement between the axes in V and H directions to ensure that the
centre of the contact pattern moves along the longitudinal line of the gear t o o t h , are
given b y :
dV άΗ
= _
JJ7· = 0. 0498905, dT °· °704864
The rates of change of the second order contact parameters with respect to s* are il-
lustrated below:
V AND H CHECK 91
άυ d/2
- = 1.023777mm ,
as d* T = — 3. 22410e - 2,
(2)
άκ dy
= — 0.0467847mm , — 1. 53912*? — 5 / r a d / m m
dT 7 d5* l(d?>(1>)2J
The results from T C A program are given below. Before V and H movement, the
contact parameters are listed in Table 3. 6 as follows:
Table 3. 6 Contact Parameters at the Reference Point

φ™ -30° -20° -10° 0° 10° 20° 30°
X -0.12528 -0.03919 -0.00546 0 -0.00375 -0.03401 -0.11961
Y -4.01371 -2.79949 -1.46449 0 1. 60079 3.34217 5.22547
h 17.8499 17.8952 17.9272 17. 9480 17.9605 17.9683 17.9755
K 15.078° 16.772° 18.612° 20. 604° 22. 750° 25.051° 27.498°
Δφ™ - 1 2 . 1 8 9 " -5.278" -1.286" 0 -1.230" -4.826" -10.687"
If the both moving distances of the contact centre to the toe and in the heel are 1
m m , the required moving distances in V and H directions are·
To the t o e : V = —0. 049262 mm H = 0 . 069969 mm

In the heel: V = 0 . 050534 mm H = - 0 . 0 7 1 0 2 9 mm
The results from T C A are listed in Tables 3. 7 and 3. 8:

Φ" -30° -20° -10° 0° 10° 20° 30°
X -0.78405 -0.90258 -0.96661 -1 -1.02910 -1.08193 -1.18713
Y -3.96362 -2.76418 -1.44586 0 1. 58014 3.29883 5. 15743
h 17.8935 17.9353 17.9633 17. 9797 17.9874 17.9899 17.9915
K 15. 150° 16. 838° 18. 669° 20. 652° 22. 788° 25. 076° 27. 510°
Αφ™ - 1 2 . 6 2 4 " -5.471" -1.335" 0 -1.277" -5.011" -11.096"

<fl·» -30° -20° -10° 0° 10° 20° 30°
X 1. 0 3 0 2 4 0. 97807 0. 97609 1 1.02297 1.01656 0.95173
Y -4.06502 -2.83573 -1.48366 0 1.62210 3.38696 5.29586
h 17.8059 17.8545 17.8902 17.9153 17.9325 17.9453 17. 9581
K 15. 008° 16. 709° 18. 556° 20. 558° 22. 717° 25. 030° 27.491°
Αφ™ - 1 1 . 7 3 8 " -5.078" -1.237" 0 -1.181" -4.635" -10.264"
If the both moving distances of the centre point of contact to the toe and in the heel
are 10 m m , the required movements in V and H directions from T C A a r e :
T o the t o e : V = —0.44216 mm H = 0 . 66324 mm

In the heel: V = 0 . 57114 mm H = - 0 . 77151 mm
After V and H m o v e m e n t s , the contact parameters are illustrated respectively in T a -

bles 3. 9 and 3. 1 0 :
0» -30° -20° -10° 0° 10° 20° 30°
X -9.15922 -9.50542 -9.77795 -10 -10.1974 -10.3933 -10.6290
Y -3.56751 -2.48790 -1.30146 0 1. 42286 2.97118 4.64640
h 18.2522 18. 2542 18. 2382 18.2068 18.1635 18.1123 18.0579
K 15. 860° 17. 506° 19. 288° 21.212° 23. 283° 25. 498° 27. 854°
A<p™ - 1 5 . 9 8 7 " -6.960" -1.704" 0 -1.638" -6.435" -14.239"
Φ» -30° -20° -10° 0° 10° 20° 30°
X 8. 96705 9. 29007 9. 64368 10 10.32861 10. 59755 10. 77448
Y -4.58429 -3.20592 -1.68119 0 1.84538 3.85952 6.04317
h 17.3968 17.4686 17.5318 17. 5887 17. 6423 17. 6964 17.7551
K 14. 430° 16. 202° 18.143° 20. 260° 22. 555° 25. 023° 27. 653°
Δφ™ -6.803" -2.892" -0.694" 0 -0.651" -2.549" -5.664"
V AND H CHECK 93
From TCA results it is known that the average values of the displacement in V and H
directions for the contact centre to move 1 mm to the toe and in the heel are very
close to the values of τ τ and - p - which are found from third order contact analysis,
and the average values of the changing amount of the second order contact situations
can compare very well with the rates of change of these parameters found from third
order contact analysis. Even if the moving distance of the centre point of contact is
increased to a considerable amount, the solutions found from this method can still
compare well with those from T C A program.
Concave Side Convex S i d e
0 f /o /S 20 2f
' « ■ * »
Fig. 3. 11 The contact patterns before and after V and H movements
The real contact patterns of the gear pair under the theoretical mounting distances
and after V and H movements, which are obtained from running t e s t , are illustrated
schematically in Fig. 3. 11. The movements in V and H directions are just 10 times
of the values of -Ϊ—7 and -5—7, so the moving distances of the centre point of contact
to the toe and in the heel along the longitudinal line should be approximately 10 mm
in each case. As shown in Fig. 3 . 1 1 , the moving distances of the centre points of the
contact pattern and the changes of CPP directions compare quite well with the ana-
lytical results.
3.6 CONCLUSION
In this chapter an accurate analytical method is presented for the analysis of the dis-
placement rates in V and H directions with respect to the moving distance of the cen-
tre point of contact pattern of the gear flank along the longitudinal line > and rates of
change of the second order contact parameters of the gearing. From the examples of
calculation and experiment it is known that this analytical methld is a reliable and
valid means for the investigation of the sensitivity of the performance of mismatched
gearing to the misalignments. The solutions found from this method compare well
with those from the TCA program and experiment, although the analysis is carried
out at only the reference points, and the centre points of contact patterns have been
moved a considerable distance from this point. All the results can be directly found
in parametric forms. Together with the results found from the analytical method
which is presented in Chapter 1, a more comprehensive object function for the opti-
mization of machine-setting parameters can be directly composed.
4
A Direct Method for Determining

the Parameters of Mating Tooth Surfaces
According to
Predetermined Contact Situations
4.1 INTRODUCTION
From differential geometry point of view, the contact parameters of a pair of mis-
matched tooth surfaces can be classified into the first, second, third or higher order,
respectively, and these are determined by the geometry parameters up to the first,
second, third or higher order. The position of the centre point of contact pattern is
determined by the first order parameters; the moving speeds and directions of the
contact points on tooth surfaces, the length and width of the instantaneous contact
field, and the relative angular acceleration between gear axes are determined by the
second; whilst the rates of change of the second-order contact parameters either dur-
ing the running process or under vertical ( V ) and horizontal ( H ) check are deter-
mined by the third-order parameters. This chapter will discuss the problem concern-
ing the determination of the geometric parameters of the mating tooth surfaces of a
mismatched gear pair directly according to some predetermined second-order contact
parameters1-12-1.
The second-order parameters of mismatched tooth surfaces are generally determined

as follows1-7-1: suppose Σ ( 2 > is a known tooth surface (Fig. 4 . 1 ) ,a reference point M
is chosen on it for calculation. Firstly, the second-order parameters of an imaginary
tooth surface which can make a theoretical line-contact and uniform transmission
with Σ < 2 ) are calculated. Secondly, some curvature modifications are done on the pa-
rameters of the imaginary tooth surface, and the modified parameters are used as
Fig. 4. 1 An illustration
of point-contact flanks
those of practical mating tooth surface Σ α > . Finally, tooth contact analysis is per-
formed to establish if the modifications are suitable. Obviously, the traditional
method has a drawback in that the second-order contact parameters cannot be direct-
PRESETTING CONTACT SITUATIONS 97
ly controlled, the effects of modifications can only be seen after tooth contact analy-
sis. This makes the determination of the modification amounts very difficult, and
many trials are usually needed before desired transmission performance in a local
sense is obtained. An alternative procedure is suggested in this chapter, for which
three second-order contact parameters (the moving direction of the contact point on
the gear flank, the length of the instantaneous contact field or its projection length
on the longitudinal direction of the tooth surface, and the angular acceleration of the
gear relative to the pinion) are to be predetermined, while the second-order geomet-
ric parameters of the pinion flank are directly determined depending on the required
contact performance. In this w a y , the performance of a gear pair in a local sense can
be effectively controlled, and the entire analytical procedure can be greatly reduced.
4. 2 T H E BASIC F O R M U L A E O F P O I N T - C O N T A C T T O O T H S U R F A C E S
Before introducing new algorithms, the basic geometric and kinematic relationships
between a pair of mismatched tooth surfaces are analysed to get the basic formulae of
point-contact surfaces. Suppose the surfaces Σ ( 1 ) and Σ ( 2 > are in contact at the refe-
rence point M , as illustrated in Fig. 4. 1. The unit vectors of their rotating axes are
denoted by a ( 1 ) a n d a ( 2 ) . Two points which are respectively fixed to the axes are ox and
o2 . The vectoro 1 o2 = L . Since the axes are fixed ones in the fixed coordinates, L i s
a constant vector.
At the moment the surfaces are in contact at M , the position vectors of the contact
point are oxM = Ra), o2M = R{2\ The angle of rotation of the pinion and gear are
(1> i2)
denoted by 9? and = w 21 ä <2) - αα) (4.1)
The velocities of following of the tooth surfaces are individually expressed by
t,«> =u21a™ XRi2)

Thus the relative moving velocity between the surfaces at M is
5<n> = 5 _ 5<i) = U21 5 x Ä<2> _ j a ) x Ä (4# 2 )
The conditions for the surfaces in contact at Mare Ra) = Ri2) + Land their unit nor-
mals n (1) = n<2> = n , if n (1) is an outward unit normal and n<2> an inward one. Since
the surfaces make a continuous contact,
dtf(1> = dtf(2) (4. 3)
and
dn (1) = dn<2> (4. 4)
will be held in the fixed coordinates. Now consider the first condition. Both dRay and
dRi2) can be individually expressed as
dÄ(1> = d r (1) + 5«> X R™dffl> (4. 5)
dfl<2> = d r(2> + una™ X Ä«>df*l) (4. 6)
where d r(1> and d r<2) are the differential moving distances of the contact point in the
coordinates fixed to the gears. Substituting them into Eq. (4. 3 ) , we have
d r (1) + ä(1> X Ä^dj*» = d r<2> + w21ä(2) X ^ »
Making scalar product of both sides of the equation with n and taking n · d r (1) = n ·
d r<2> = 0 into account lead to
(ä(1\ Ä t t \ 5)
"2i = (4. 7)
( S ( l > , Ä « \ n)
Differentiate with respect to f^l> ♦ we have

κ21 = (4. 8)
( 5 < 2 \ n , Ä<2))
where , , n denotes the derivative of w in the fixed coordinates. It can be expressed in
two forms :
df; = ^ * v"a> + 5<1> x * (4 9)

·
, v < 2 > + M2
d ^ = ^ " '5<2>x" ( 4
·10)
where V « a > and Vw ( 2 ) are the curvature tensors of E ( 1 ) and Σ ( 2 > at point M . If these
are expressed by their principal curvatures and unit vectors of principal directions,
they take the from :
Vna) = - *«> e,~ex- k?> e2 e2 (4.11)
Vn ( 2 ) = - *{» C! ii - *?> e, i 2 (4.12)
From Eqs. (4. 9) and ( 4 . 1 0 ) it is known
H r (1) - d r(2> _
Vn<1> = w + ω<21) x ( 4
^ * % * ' " " ·13)
Substituting Eq. (4. 10) into Eq. (4. 8 ) , we have
" ( 2 1 \ ±jß + unä™ X Ä « \ s ) + ί<21> · ( ~ · Vn<2> + w21ä<2> X »)

«21
( ä < 2 \ n , tf<2>)
^ , p a , , = _ Ä , ? B > (4>14)
where P < 1 2 ) = - v<2iy · Vn < 2 ) + ω(21> X n (4. 15)
^<i2> = - un a™ X P(2> - ω<21> X vi2) + u21 ä<2) X vi21) (4. 16)
During the running t e s t , the trace of the contact point on Σ ( 1 > is called the contact
point path ( C P P ) on Σ α ) > its arc length is denoted by5 ( 1 ) . Similarly, the arc length
d r(2)
of CPP on Σ ( 2 ) is denoted by s (2) . The physical meaning of , (1) is the moving veloci-
ty of the contact point on Σ ( 2 > ; its direction is naturally the direction of CPP on
Σ ( 2 > . Let tG denote the unit vector of i t ,
tG = d*<
which means
ds<2) -
άφα)
άφ{ to (4. 17)
From Eq. ( 4 . 1 4 ) ,
d5<2) _ _ n * qaz)
(4.18)
d
^n ~ tG · P(12>
s(
. dus
If the value of -r-^y obtained is negative, it means the direction of tGis opposite to the
moving direction of the contact point on Σ ( 2 > . From Eqs. (4. 2) , (4. 3 ) , (4. 5) and
(4. 6) it is known
J r(l) J r (2)
< 2 1 >
^ = ^ + " (4.19)
Suppose the unit tangent of CPP on Σ α ) is tP9 then

- _ dr(1) _ dr(1) ldsa)

tp (1) (4. 20)
~ ds ~ a<?f /άφα)
iy
vher
as'
(4.21)
άφα άφα
Define a surface Σ ( 2 1 > at point M. Its normal coincides with n , and in every tangent
direction, its normal curvature ki21) is the difference between the normal curvatures
ki2) of Σ ( 2 ) and ka) of Σ α > along the same tangent direction, i. e.
£<21> = £(2) _ £<1> (4.22)
Σ ( 2 1 > is denominated as the 'difference surface' .
For any unit tangent r , the normal curvatures of Σ α > » Σ ( 2 > a n d Σ ( 2 1 > are — τ ·
(Vw ( 1 ) · r ) , — r · (Vn < 2 ) · r ) and — τ * ( V « ( 2 1 ) · r ) , respectively. According to the
definition,
- τ · (Vw ( 2 1 ) . ? ) = - ? . (Vrä <2) · ? ) + ? · ( V n ( 1 ) · r )
From the arbitration of r it is known
Vw (21) · r = V n ( 2 ) · r - Vw ( 1 ) · τ (4.23)
Again, from the arbitration of r ,
Vn < 2 1 ) = Vn <2> - V « ( 1 ) (4.24)
Applying tP instead of τ in Eq. (4. 23) , we have
tP · Vn < 2 1 ) = tP · V n ( 2 ) - iP · V n ( : (4.25)
From Eqs. (4. 1) , (4. 9) , (4. 10) , (4. 17) and (4. 20) it is known
lp . V« ( 1 > = g o ) to ' Vn«> + ω<"> X n ^ (4. 26)
Substituting it into Eq. (4. 25)» we have
1P . Vn<-> = v^ · W 2 > g g - 5«l> X ή g S = - P < » > ^ (4. 27)
Equations (4. 14) and (4. 27) are the basic formulae of point-contact tooth surfaces
along the directions of CPP on flanks. It is seen from these expressions that they are
determined only by the parameters of the known surface and the relative movement
between the gears. It can be noticed that these two equations are valid in any direc-
tions for line-contact surfaces.
4. 3 S I T U A T I O N OF P R E D E T E R M I N I N G C O N T A C T P A R A M E T E R S
ON KNOWN S U R F A C E
Suppose the geometric parameters of Σ (2> > the axes α α> anda < 2 > , the instantaneous
gear ratio w2i and the position of the reference point M are known. This situation
means that the first-order geometric parameters of Σ α > has been determined. In or-
der to determine the second-order parameters of Σ α > > now the problem concerns as
to how many second-order contact parameters should be given, and which ones
should be guaranteed. Since the number of independent second-order geometric pa-
rameters of a surface at a certain point is t h r e e , the number of predetermined contact
parameters can be neither less nor more than three. In order to eliminate the draw-
back of traditional method, the predetermined contact parameters must have explicit
geometrical or kinematical meaning, which characterize the contact situations of the
tooth surface at the reference point, and guarantee not to lead to ill-conditioned
equations. In Fig. 4. 2 τγ and r 2 denote the unit vectors of the profile and longitudinal
directions of Σ ( 2 > · They are perpendicular to each other. From engineering point of
view, the predetermined parameters can be better chosen as follows:
1) the angle v between rx and the moving direction of the contact point on Σ < 2 >
(the tangent direction of C P P ) ;
2) the length of the major axis of the instantaneous contact field lz or the pro-
jecting length of l2 on r 2 ;
3) the instantaneous angular acceleration of the gear relative to the pinion ulx
when the reference points on both surfaces are in contact.
Fig. 4. 2 Some second-ordei

contact characteristics
Unless the moving direction of the contact point is chosen to be very close to the ma-
jor axis of the instantaneous contact field, the suggested predetermined contact pa-
rameters will never lead to ill-conditioned equations. However, from engineering
point of view, the contact situation would be very poor if the contact point moves
along the major axis of the instantaneous contact ellipse. We shall discuss below the
calculation procedure for the second-order geometric parameters of the pinion flank
to ensure the predetermined contact performance in a local sense.
From Fig. 4. 2 it is known
tG = cos υ τγ + sin υ τ2 (4. 28)
Since Σ ( 2 > is known and w2iis predetermined, P (12> and g<12> can be determined by
ds(1>
means of Eqs. (4. 15) and (4. 16). Subsequently, τ~öy can be calculated from Eqs.
( 4 . 1 7 ) , ( 4 . 1 8 ) , ( 4 . 1 9 ) and (4. 21). Then, tPcan be obtained from Eq. (4. 20). Fi-
nally, tP · Vn ( 2 1 ) can be determined by Eq. (4. 27).
Similar to Vw ( 1 ) and V n < 2 ) , Vn ( 2 1 ) can be expressed in the form
Vn(21>=-^21>i1i1-^21>i2i2
where tx and i2 denote the unit vectors of the principal directions of the difference sur-
face, k{21) and k{221) the corresponding principal curvatures. The angle between t2 and r2
is supposed to be κ. The above parameters are to be determined.
Make a scalar product of tP · Vn ( 2 1 ) and* 2 · Since Vn ( 2 1 ) is a symmetric tensor, the or-

der can be changed. Thus
i2 · Ctp · Vn ( 2 1 ) ) = tP · 6t · Vn< 21) ) = - k™ tP · t2 (4. 29)
From Fig. 4. 2 it is known t2 = cos * r2 + sin κ rx . Substituting it into Eq. (4. 29)
leads to
(cos κτ2 + sin κ r\) · (i P · Vn ( 2 1 > ) = — ^^21>(cos κ tP · r2 + sin * i P · r x )
Thus an equation between κ and £221> is obtained, as follows:
OP · Vn ( 2 1 ) + k?» tP) · r~2

tan /e = = = z (4. 30)
dtp · Vn(21> + *<21> i p ) . r x
surfaces and the load is so light that the elastic deformation of the teeth can be ne-
glected, the area where the distance between the surfaces is less then the thickness
of the compound δ can be regarded as the contact spot. The instantaneous contact
spot can be taken as an ellipse and the length of its major axis can be expressed as
follows :
(4.31)
If the value of/ 2 is predetermined, £ 2 21) can be directly found from Eq. (4. 31). Then,
by substituting it into Eq. (4. 3 0 ) , κ can be determined. On the other hand, if the
predetermined parameter is the projection length of l2 > another equation is obtained:
2
< 8<9οcos K
4 Ι ι ) = 2« ^ α 3 2 )
B
Using it together with Eq. (4. 30) , the values of κ and £221) can be determined. The
simplest method, the authors believe, to solve this set of nonlinear equations is iter-
ation. It converges very fast.
Then the unit vectors of the principal directions of the difference surface can be
found as follows:
i, = cos K r, — sin K r2 )
- . - , - \ (4.33)
t2 = sin K τχ -\- cos κ τ2 J
As for Eq. (4. 29) , but considering tl direction,
h · CtP · Vn ( 2 1 ) ) = - k^t, -tP
Therefore, another principal curvature of the difference surface can be found as fol-
lows:
h - ( tP - Vn ( 2 1 ) )
k[21) = -
Along the directions of tY and* 2 , the normal curvatures of Σ ( 2 > are — tx · (Vn <2> · i x )
and — t2 · ( V n ( 2 ) · i x ) , respectively. The geodetic torsion of E ( 2 > alongi! is — t2 *
( V n ( 2 ) ♦ ϊχ) . Therefore, the normal curvature of 2 ( 1 > alongi 1 and t2 will be
*i<l> = - i i · ( V n ( 2 ) · tO ~ k[21> |
- Γ (4.35)
(2)
* £ = - * i · (v« ·ί 2 ) - *?»
and the geodetic torsion along tx will be

4 ° = - i 2 · ( V n ( 2 ) -tO (4.36)
With these values, the principal directions and curvatures of Σ α > can be calculated
by using formulae presented below. T h e directed angle from e2 to i 2 is
i 2r-a>
β== tan (4 37)
~ 2 ~>>_V> '
The medium and difference of the principal curvatures of 2 ( 1 > are
£ _L £ k\l) + k^

Ha> = *ι + *2 = h ; '■ (4 .38)
α)
A(l) _ 7,(1) Γί
K U d 9 ;
2 sin 2/? '
Therefore, the two principal curvatures will be
(4. 40)
and the unit vectors of the responsible principal directions of Σ ( 1 > can be expressed
by
ex — cos ßt1 — sin ß t2 ]

• />- , o- r (4.41)
e2 — sin p h + cos /? £2 J
Thus we have obtained all the second-order geometric parameters of Σ α > at point M.
4. 4 S I T U A T I O N OF P R E D E T E R M I N I N G C O N T A C T P A R A M E T E R S
ON U N K N O W N S U R F A C E
In some cases such as cylindrical worm gearings, the worm flanks Σ α > are usually
supposed to be the basic surface, and the modification is carried out on the wormheel
flank Σ ( 2 ) . Therefore the parameters of Σ (1> are known» but those of Σ (2> are to be
determined. It is more convenient to predetermine some contact parameters on Σ ( 2 > .
The parameters to be guaranteed are just the same as suggested in the above section.
Below we shall discuss calculation procedure for the second-order geometric parame-
ters of Σ ( 2 \
Similar to Eqs. (4. 14) and (4. 27)» we have
^.P«.> = _S.5«.> (4.42)
to ' V n m > =P < 2 1 ) ^dj< 2 ) (4. 43)
wher
pan = wai> . V n a > _ ω<2ΐ> χ „ (4 44)
g<21> = «21 am X Ri2> + ω<21) X 5<l> - aw X 5 (21) (4. 45)
ds(2) _ n » qm) + p<21) » P (21)

(4.46)
^ ~ ϊο · P (21)
Similar to Eq. (4. 30), we have for the present situation
ÖG · Vn<21> + k™ tG) · τ2
tan K = (4. 47)
QG · Vn (21) + k™ fc) · ? t
Now, if the value of lz is predetermined, kl21) can be directly obtained from Eq. (4.
31), and then κ can be determined by substituting kl2O into Eq. (4. 47). Otherwise
Eqs. (4. 32) and (4. 47) have to be used together. The other steps are very similar
to those presented above» and therefore will not be discussed here again.
Here the drive side of a pair of hypoid gears in mesh is taken as a calculation example
to demonstrate the method presented in this chapter. The relative position between
gear axes are illustrated in Fig. 4. 3. The basic parameters of the gear pair have been
presented in the numerical example in Chapter 1. When the tooth flanks are in con-
tact at the reference point M , the instantaneous gear ratio is equal to the theoretical
one, and w2i = 0.1621622. The y and z coordinate axes are respectively along the op-
posite directions of α α> and a<2). The x axis is perpendicular to them. The root cone
apexes of the pinion and gear are ox and oz. Their position vectors are ογ · ( 0 , —26.
63178, 0) , o2 : ( —35, 0, 0. 43869). When the tooth surfaces are in contact at the ref-
erence point M , the position of which is chosen in accordance with the desired centre
point of the contact pattern on the gear tooth surface, the position vectors of the
contact point are:
ao>
Fig. 4. 3 The gear pair

for calculation
Ril) = 5 . 80467 1 + 151. 43496 7 ~ 31.19278 k

R™ =40. 80467 1 + 124. 80318 7 - 31. 63147 k
The unit normal and the unit vectors of profile and longitudinal directions are as fol-
lows:
n = 0 . 567887 Ί - 0. 809528 7 - 0.148889 k

?i = - 0. 276324 1 - 0. 017110 ~j - 0. 960912 k
τ2 = 0 . 775338 ι + 0. 586832 J - 0. 233409 £
The principal directions and curvatures of Σ<2> at Mare listed below:
ex = 0 . 823105 t + 0. 558167 7 + 0 . 1 0 4 6 3 1 k
e2 = - 0. 001597 1 - 0.181970 7 + 0 . 983303 k
k{2) = 0 . 00682051 *?> = 0. 00381927
The predetermined second-order contact parameters are as follows:
dV 2>
v = 0°, 5 = 16. 8 mm, ■ \x) 2 = — 0. 0004
Now we begin to calculate the second-order geometric parameters of the pinion sur-
face. First, from Eqs. (4. 1) and (4. 2 ) ,
w<2i> = 7 _ 0.162162 k
ϋ<2ΐ> = - io # 9544 Ί - 6. 61697 7 ~ 5. 80467 k
Consequently, from Eqs. (4. 15) and (4. 16),
P<i2) = _ 0# 354901 1 - 0.139671 7 ~ 0. 594239 k

il2)
q = 0 . 049921 1 + 5. 041969 7 + 20. 238358 I
Then, from Eqs. (4.28), (4.18), (4.17), (4.19), (4. 21) and (4. 27),
tG = - 0. 276323 1 — 0. 017110 J — 0. 960912 k

ds<2>
10. 524006
dr(2)
d^ n
- 2. 90803 ι - 0.18007 J - 10.11265 k
dr (1)
d^ n - 13. 86246 * - 6. 79704 7 ~ 15. 91732 k
ds(1)
d<ffl)
22.17495
tP · Vn ( 2 1 ) 0. 0160046 ϊ + 0. 0062986 7 + 0. 0267978 k
Fig. 4. 4 An illustration of some second-order contact parameters
Set δ = 0. 01 , from the Eqs. (4. 30) and (4. 32) we have
K =17.92483°
ki21) =0.000256598
Then using Eqs. (4. 33) - (4. 3 9 ) ,

h = - 0. 501536 1 - 0.196888 7 - 0 . 842435 k

0. 652660 1 + 0. 553081 7 — 0. 517818 k
£<21>
0.0325392
=
- 0. 0276000
0.00544401
*?- - 0.00145152
ß = - 2. 510389°
- 0.0165856
- 0.0110780
Finally, the second-order parameters are obtained from Eqs. (4. 40) and ( 4 , 4 1 ) , as
follows:
- 0.0276636
0. 00550764
- 0. 472468 1 - 0.172474 7 — 0 . 864307 k
e2 0. 674001 1 + 0. 561174 7 - 0. 480422 k
Some contact situations using this scheme determined above, are illustrated in Fig.
4.4.
The validity of the algorithm has been proved by the results from the tooth contact
analysis ( T C A ) program and from experiments which have been presented in Chap-
ters 1 and 3.
4.6 CONCLUSION
A direct method for accurately determining the second-order geometric parameters of

the mating tooth surfaces of a mismatched gear pair according to three predetermined
second-order contact parameters is presented in this chapter. The analytical treat-
ment is quite different from those generally used and are known to the authors from
the open literature. The advantageous characteristic of the procedure presented is
that by means of suggested algorithm, not only can the second-order contact perfor-
mance be strictly controlled in advance, but also the local synthesis is no longer re-
quired. As a r e s u l t , the calculational procedure can be greatly reduced. On the basis
of this method, an optimal synthesis on the third-order contact performance can be
performed without changing predetermined second-order contact situations.
5
A Simple Method of Obtaining

Machine-Setting Parameters
for Spiral Bevel and Hypoid Gears
5.1 I N T R O D U C T I O N
The cutter and machine setting parameters are generally calculated using the Calcu-
lating Instructions developed by Gleason Works ( S F T , S G T , H F T , H G T , S F M ,
S G M , H F M and H G M ) . The authors believe that there are some drawbacks with
these methods. Some of these a r e : the formulae are complicated; although the intro-
duce of imaginary tooth surface can slightly simplify the calculating operations in the
previous s t e p s , it leads to many difficult and undesired situations in the further ana-
lysis of tooth contact situations; and some methods cannot make a full use of ma-
chine-setting measures. In order to solve these problems, some new algorithms are
developed in this chapter1-13-1. Since the second-order parameters of the pinion tooth
surfaces can be obtained directly according to predetermined contact situations by
means of the algorithms presented in Chapter 4 , the authors believe it is not neces-
sary to distinguish whether the gear pair is spiral bevel or hypoid, Formate or gener-
ated. This chapter will introduce the basic principles for the determination of ma-
chine-setting parameters, and we will find that all the calculation methods are based
on the same principles, no mater what kind of generator is used. When a bevel gear
generator with cutter-tilt mechanism is used, the new method can provide at least
three freely selected setting parameters, i. e. more than those available for the meth-
ods developed by Gleason works. As a result, a better solution can be expected to be
found from optimal synthesis. Especially, for some kinds of generators, the range of
cutter tilt angle is affected by the direction of swivel angle. Sometimes no summaries
found from Gleason Calculating Instructions can be realized on these machines. On
the other hand, this problem can be solved by using the new method. According to
the new method, pinions of Formate hypoid gears can be machined on generators
with neither cutter-tilt nor modified-roll mechanisms. This is not possible if Gleason
Calculating Instructions are used. The basic principles also allow us to combine the
individual methods together if a generator being used has more functions than one.
For example, if a machine tool has both cutter-tilt and modified-roll mechanisms, as
for a CNC generator, the new method can guarantee to make a full use of these func-
tions presented by the machine tool to get the best result.
5. 2 T H E MACHINE R O O T ANGLE AND FORMING POSITION O F

REFERENCE POINT
When a pinion is machined on a generator which has no cutter-tilt mechanism, the

machine root angle T/is just equal to the root angle of the pinion 7R. For the machine
with cutter-tilt mechanism being used, in order that both outer and inner tooth
depths conform to the design, the projection of the tool nose velocity at the mean
point of the face on the horizontal plane should be approximately parallel to the root
cone. The vector of the cutter axis can be determined by horizontal and vertical cut-
ter tilt ////and μν (Fig. 5. 1 ) ; both are freely-chosen parameters. From Fig. 5. 1 it is
known that the projection of the tool nose trace on the horizontal plane is an ellipse,
and the tangent of the ellipse at a point which is on the generatrix passing through
point M should be parallel to the root cone of the pinion. The tangent of the tool
nose trace at a certain point can be expressed by
t = — sin Θ cos μνί + (cos Θ cos μΗ + sin Θ sin μν sin μΗΥ}

+ (cos Θ sin μΗ — sin Θ sin μν cos ////)£ (5. 1)
where Θ is an undetermined parameter. Let ψΡ denote the mean spiral angle of the pi-
MACHINE-SETTING PARAMETERS 115
nion. Strictly, it should be the root cone spiral angle. Since X—gear pairs are widely
used and the root cone of a pinion is usually close to the pitch cone, the difference
can be neglected from engineering point of view. Thus the parameter Θ can be deter-
mined by
— tx = sin ψΡ
where tx denotes the component of t on x axis. From Eq. ( 5 . 1 ) ,
sin Θ cos μν = sin ψΡ
Therefore,
. Ω sin ψΡ n v c o s 2 uy — sin 2 φΡ
sin Θ = —, cos Θ = - — ^ (5. 2)
cos μν cos μν
From Fig. 5.1 it is known
Ύκ = Jf + t a n " 1 ^
From Eqs. (5. 1) and (5. 2) it is known
-\tz ^ _, sin ψρ
φΡ sin μν
A
tan l
- = μΗ - tan" 1 -^
ν Ρ
y 2 2
v c o s μ — sin ψ
Thus the machine root angle should be
+. . -i sin ψρ sin μν
1
yf = Ύκ - μΗ + tan" ^ w- (5# 3 )
Vcos // y — sin 0i»
2 2
After cutter tilt, the unit vector of the cutter axis will be
/ = sin μ ι + cos μ sin μ ] — cos μ cos μ k (5. 4)
ν ν Η ν Η
Since both μν and μΗ are freely chosen parameters, the normal tilt is no longer equal
Cutter
M (Cutting)
Cutter Nose Trace

M (Engagement)
Fig. 5. 1 An illustration of the relative

position between the cutter and blank
to the difference between the normal pressure angle of the pinion tooth surface and
the pressure angle of the cutter. Thus the forming position of the reference point has
to be determined by calculation. Figure 5. 2 illustrates the situation of the pinion and
gear in contact at the reference point M. In order to move the pinion from its posi-
tion of engagement to the position of machining, the pinion must turn — 7/ about x
axis , and then turn an angle e about its own axis αψ . Now we set to finding out the
unknown parameter e . Cutting edges rotating at a high speed form a circular cone,
denominated as generating flank Σ ( / > · The condition for the pinion tooth surface
Σ ( 1 > in contact with Σ ( / > at the reference point M i s that after the above mentioned
rotation, the normal of the pinion tooth surface w/° must be in line with that of the
generating flank n ( / > . Since both normals are unit ones, their projections on the cut-
ter axis must have the same value, i. e.
Fig. 5. 2 The coordinates

of engagement
η/Ώ · / = — sin ψρ (5.5)
where ^ d e n o t e s the pressure angle of the cutter, η/Ώ the unit normal of Σ α > at Maf-
ter the turns. The turns can be expressed as
„«> = φ n (1) (5.6)
where
cos e 0 sin e
Φ = — sin e sin Jf cos Jf cos e sin 7f (5.7)
— sin e cos 7f — sin 7f cos e cos Jfm
Substituting Eqs. (5. 4 ) , (5. 6) and (5. 7) into Eq. (5. 5 ) , we have
(ni n cos e + n<n sin e) sin// v + (— n<n sin e sin yf + n<n cos yf
+ η£η cos e sin Ίf) cos μν sin μΗ — (— n(xiy sin ε cos 7 /
— n^ sin T/ + n^cos e cos T/) cos μ ν cos μΗ — — sin ψρ
where n£ n , n^n and n<n are the components of n a > in the engagement coordinates. The
root of this equation can be written a s :
e = 7Γ — tan" — — — tan Yj- (5.8)

JU} +V2f-W} Uf
where
Uf =n< 1) sin μν + η<η cos μν cos ( ? / + A«//) ]
Vf =niiy sin μ ν — w<° cos μ ν cos (T/ + //#) (5.9)
W/ = — n<° cos //y sin (T/ + μΗ) — sin 9?p
After obtaining the value of ε , η ( / ) can be determined by formulae (5. 7) and (5. 6).
Similarly, we can get the position vector and the unit vectors of the principal direc-
tions of S ( 1 ) a t M i n the machining coordinates, as follows:
Ra> = φ#α>, ~e i -=*ii. ί?> = Φ'β2 (5.10)
5. 3 THE DIFFERENCE SURFACE AND GENERATING FLANK
The generating flank Σ ( / y is a circular cone, formed by the rotation of the cutting
edges at a high speed. Its principal directions at a point are respectively along its
generatrix and latitude. At the reference point, the unit vectors of these directions
are s
-(/) = /Xn">
2
c o s <f>p (5.11)
e[n = ΪΚ } X n (/) (5.12)
As it is known from the local point of view, the pinion tooth surface Σ α > can be con-
sidered as a pile of the generating flank and difference surface, see Fig. 5. 3. This is
a very important concept, and all the formulae for the determination of the cutter
point radius and machine setting parameters are based on this concept.
Let ?! denote the unit tangent vector of the instantaneous contact line (see Fig. 2. 4) ,
t2 = ny > X tx
Fig. 5. 3 A pile of generating

flank and difference surface
will be the unit vector corresponding to the maximum normal curvature of the differ-
ence surface Σ α / > · As mentioned in Chapter 4 , the curvature tensor of the differ-
ence surface equals the difference of contact surfaces,
Vn(1) = Vn(1/) + Vn(/)
Since the normal curvature of Σ α / M o n g o l is equal to zero, and the normal curvature
of the generating flank Σ ( / > along e[f) is equal to zero, they can be respectively ex-
pressed a s :
Vn</>=-^/eK>^/)
V«(1/) = -kpt2t2
where £/denotes the normal curvature of Σ ( / > along e\n, kp the normal curvature of
Σ ( 1 / > along t2. Therefore, the curvature tensor of Σ α > at the reference point can be
expressed a s :
V n ( 1 ) = - kfe\n e\n - kp t212 (5.13)
Suppose the angle between e\n and tx is Θ (see Fig. 5. 4 ) , the normal curvature and
geodetic torsion of Σ α > along e\n will be
Fig. 5.4
£;;/> = kp sin 2 Θ , rj</> = — kp sin Θ cos Θ (5. 14)
and the Gauss curvature of the pinion tooth surface at point M is
K™ = kfkpsm2e (5.15)
On the other hand, since the principal curvatures and directions of Σ ( 1 ) are k n o w n ,
the three parameters mentioned above can be obtained as follows:
k% = k^G\f) · 'en2 + *ίι>(ί{/) · 'e^y (5.16)
r5<V> = *u>(-</> . -a)) (-</) . 3 » ) + Λα>ο</> . ί<ι>) (£</> . ί<ι>) (5# 1 7 )
K™ = *{l> *?> (5.18)
Thus the unknown parameters in Eqs. (5. 14) and (5. 15) can be determined by :
7<i) ,<n
j£ _ — k-e^ k-ey
(5.19)
sin 2 0
V tan 1 (1)
kf = -τττ*
7 V Θ= TvT~f kP =
r-(/>
Fig. 5. 5 The addendum

of the cutter
From Meusnier's theorem it is known that the radius of the generating flank at the
point corresponding to M will be
c o s <pp
R = (5. 20)
From Fig. 5. 5 the cutter addendum is known to be
ha = £}i> cos aR - T/) - R% sin (T s - Ύ/) (5.21)

Therefore, the cutter point radius should be
sign Ckf) ha sin ψρ

RP= R ; (5. 22)
eg*cos (?* - T/) - e%> sin (7R - T/)
For the generators without cutter-tilt mechanism, the cutter addendum will be
K = R% (5. 23)
and the cutter point radius will be
RP= R - sign (k/) ha tan φ» (5. 24)
The unit vectors of the principal directions of the difference surface are:
tx =i[n cos Θ + etf^sin Θ

tz =e(2f) cos Θ — e{f) sin θ Γ
5. 4 MACHINE SETTING PARAMETERS FOR GENERATORS WITH

NEITHER MODIFIED-ROLL NOR WORKHEAD-VERTICAL-FEED
MECHANISM
These machines include the generators with and without cutter-tilt mechanism (For
the latter, set both //vand ////equal to zero in the equations mentioned above). In or-
der that the required first and second order geometric parameters can be obtained,
three conditions as follows have to be implemented: i) the relative velocity vilf > be-
tween the tooth surface and generating flank is perpendicular to the normal n ( / > , ii)
vector Pilf) is perpendicular to the tangent of instantaneous contact line; iii) the
principal relative curvature |P ( 1 / > | V &ιη · Ρ α / > + n ( / > · g a / > ) is equal to £P . The
necessity of the second and third condition can be found from Chapter 2. Without
losing generality, the angular velocity of the pinion can be supposed to be unity. The
angular velocity of the cradle is denoted by <t)f. The blank offset and root apex be-
yond machine centre are denoted by, respectively, EP and X (see Fig. 5. 1). Since
vaf > J_ n ( / > , it can be supposed that
vaf) = μχ~β\η + μ2~β\η (5.26)
The velocity of following of the pinion tooth surface at point M is
νγ> = αψ X Rf (5. 27)
where
ä> n = cos T/7 — sin 7fk (5. 28)
denotes the unit vector of the pinion axis. Therefore, the velocity of following of the
generating flank at M can be written a s :
i ( / ) = νγ' - μχ e\n - μ2 e\n (5. 29)
Since νσ) J_ k , by making numerical production of both side and k , we have
ΌΦ e(f)
f*i = -cn- &Jh (5.30)
viz e\z
If the machine has no cutter-tilt mechanism, eY} is perpendicular to k , and μχ is only

determined by the pressure angle of the cutter, this being a constant here.
The second condition P ( 1 / ) · ~tx = 0 can be expressed as (see Chapter 2)
(5 . v - < / > _ - j p χ -</> _ ω/j χ "</)) . - t i = 0
Substitute Eq. ( 5 . 26) into this equation,
tt/fti^ + ä> n X n ( / ) + « / i X w ( / ) ) · ίL = Ö
Then substitute Eq. (5. 25) into this equation, we have
-*/sin Θ (ä}n, nif\tO

(5 31)
· ' " *(!.*<»*>- α , η - , ο ·

Substitute it into Eq. (5. 29) ,
cos
5J» - μχ~e[n- μ2 e\n = « , [ ( * # - * If* + (£P ~ W>T1
Spreading this equation according to the components of i and j , we have
v% ~ μι e[V ~ μ2 eg' = «,(Ä£> - X cos T,) (5. 32)
v% ~ Mi eg* - μ2 e%} = <of(EP - K£>) (5. 33)

Set
G-i — — ^ 7 7 , Cz2 — ^(7T> tx3 — — » ^4— — — Co. 3 4 )
and substitute them into the third condition, a quadric equation in one unknown is
obtained:
Ρι/4 + Ρ2Μ2 + Pz= 0 (5. 35)
where
Λ =k} + G\{k X n<'>)2 - 2Gzkfe[V + *,(*, + G,Gze^ - G,«£>)

P 2 = 2 [ G , G 4 a X n >) - *,(SjP . iK ) ~ G 4 *,*ii> + G8(5y> X n ( / ) )
(/ 2 }
• (Ϊ X n ( / ) ) ] + ^ [ ( β , σ , + d G 4 ) e\V ~ G4e<£> + G 8 (I,5< / > f 5y>)]

p , = G j a X n ( / ) ) 2 + 2G4(5}1) X n ( / ) ) · (Ϊ X n ( / ) ) + (SjP X n ( / ) ) 2
+ *,[G,G 4 «ii> + G 4 (I,5 </> ,5y > ) + (5y > ,5 < / > ,5y > )]
(5.36)
For the machine without cutter-tilt mechanism, Gx = 0 ,Ρχ = 0, hence
^2=-p^ (5.37)
If the value of cutter tilt is rather small, the absolute value of Piis very small. In or-
der to enhance the computational accuracy and eliminate invalid root, the solution
should be chosen as follows:
2P 3
μι (5.38)
P2+ \/Pl - 4ΛΡ.
Then, we have
Mi =MzGl +G2
v% - μι6[ϊ - μ2β\ϊ - RW
fy <°f L
X = (5.39)
ω/cos Jf
v% - the& - the& + R%*>f
0)f
The position vector from the centre point of the cutter C to point M (Fig. 5 . 1 ) is
(5.40)
kf t a n 9?p
Therefore, the vertical and horizontal components of the position of the centre point
Q , about which the cutter tilts, will be
V =EP-R% + Tx + U0fx
(5.41)
H =X cos yf + R% - T y - U0fy
where U0 denotes the distance from the centre point of the cutter C to the centre point
of tilt Q . The radial and polar angle can be subsequently determined as follows:
SP=Jv2 + H2
(5.42)
q = 9 0 ° — tan•iK
The tilt angle (the angle between the axes of the cutter and the cradle) is
= r»oc 1
(-Λ) (5.43)
and the basic swivel angle is

q — tan λγ , (Λ > O
q - tan^y + 180% (Λ < - e)

) = 0 , (l/.l < e , | / , | < c ) (5. 44)
f
q + tan" 1 ^ - 90% ( / , > *)
Jy
f
q + t a n - 1 ^ + 90% (/, < - «)
I Jy
where e is a small positive value which will not be taken as zero by a certain comput-
er. If the value of j is negtive, it should be increased by 360°. In order to ensure the
required tooth depth, the retreating distance of the sliding base from the cradle will
be
XBP = R% - Tz + X sin yf - U0dl - cos O (5.45)
Thus all the critical parameters have now been obtained. The transformation of
these parameters into a summary for individual generators can easily be done by con-
sulting their instructions.
5. 5 MACHINE SETTING PARAMETERS FOR GENERATORS WITH

MODIFIED-ROLL MECHANISM
Here two groups of generators are involved: machines with both cutter-tilt and mo-
dified-roll mechanism and machines with modified-roll but without cutter-tilt mecha-
nism. If a machine with modified-roll mechanism is used, the value of blank offset
can be freely chosen from the view point of ensuring the required first and second or-
der parameters of the pinion flank. The reason as to why it is EP9 not X to be chosen
as freely-chosen parameter» is that sometimes the polar angle q is very close to 90°,
and the other setting parameters are very sensitive to the change of X . In this case,
it is difficult to choose a reasonable original value of X . Now we consider the algo-
rithms for determining the machine setting parameters of these generators. At the
first several steps, the formulae for these machines are identical to those for ma-
chines with neither modified-roll nor workhead-vertical-feed mechanism which are
presented in the above section. After obtaining the values of Gx, G2, G3 and G4 from
Eq. (5. 34) and the value of EP being chosen, the value of μ2 can be determined by
substituting Eq. (5. 39) into Eq. (5. 33) :
v%-Gte%>- GACEP- R%)

μ2= (5.46)
G 3 ( £ P - ^ > ) +GX «£> + «£>
Then the values of μγ ,o>/and X can be obtained from Eq. (5. 39). It should be point-
ed out that all these formulae are based on the first two conditions to guarantee the
required first and second order geometric parameters, which have been mentioned in
the above section. In order that the third condition can be implemented, the cradle
must have an angular acceleration. When the cradle is turning at a changing speed,
the expression of qaf) will be (see Chapter 2)
- = -y> χ "</) + Wfi χ -<ι> + mf l χ #</> (5# 4 7 )
where
( / >
k X £ = - — (5.48)
in which t> (/) can be determined by Eq. (5. 29). Paf) can be obtained as follows:
p =- μ2 kf'e^P - 5> n X n ( / ) - a>fl X n ( / ) (5. 49)
If a machine without cutter-tilt mechanism is used, its expression can be simplified

to:
pa/) = _ -a> χ -(/> _ £ 4 j χ "</) (5# 5 0 )
The angular acceleration of the cradle with respect to the pinion can therefore be de-
termined by substituting Eq. (5. 47) and the obtained values into the third condition
for ensuring the required second-order geometric parameter of pinion tooth surfaces.
This condition is that the principal relative curvature | F ( 1 / ) \2/(var> · Par> + ησ> ·
(1/)
<7 ) is equal to kp (see Section 5. 4 ) . After simplification, the angular acceleration
of the cradle can be expressed as follows:
ω/{ρα/> . p _ Ä# [5 . p + ( n </>,Sy> ,£</>) + o> / (n </) , i , t # > ) ] }
*>/ =
^(-</) ."(/))
(5.51)
We consider below the procedure for determination of the machine-setting parame-

ters to ensure the required angular acceleration of the cradle. Figure 5. 6 is an illus-
tration of the principle of modified-roll mechanism, where ^ d e n o t e s the rotating ra-
dius of the roller of the mechanism, 6b the phase angle of the roller, and Rc the pitch
radius of cradle worm wheel. From the illustration it is known that the additional ro-
tation angle of the cradle is
/> _ ^ ( c o s Qb — 1)
Αφσ> = Rc
(5.52)
T h u s the angular acceleration of the cradle will be
— eb cos Qb . 2 (5.53)
*»/ = ■£ O / · *c · ib)
Fig. 5. 6 The principle of

modified-roll mechanism
When the reference point on the tooth flank is formed, the foller is at either the low-
est or the highest point, which means cos Qb = ± 1. Therefore,
Heb=:¥ ^f^f (5.54)
where -rf is a constant for individual machine tool, can be obtained from the instruc-
tion. Set
the values of eb and ib can subsequently be determined. If the value is positive, the
roller should be at the highest point for machining left-handed pinion and at the low-
est point for right-handed one, and vice versa. The calculations of other setting pa-
rameters are similar to those mentioned above and therefore not discussed here
again.
5. 6 MACHINE SETTING PARAMETERS FOR ALLCONE METHOD
By using allcone method, the workhead has a vertical movement during the generat-
ing process. Thus the following velocity of the reference point on Σ α > is
5jP = Sj» x *JP + μ3ϊ (5.55)
Consider the following velocity of the generating flank,
f)
af" X Rp + μ,Ί- Mle{ - μ2~β{2η
= «/[ W - X cos y/)i + (EP - RYJ)J ] (5. 56)
Expanding it according to the component of j leads to
φ » , φ » , 7 ) - G2*g> - G 4 CEP - /*£>)

μ2 = (5. 57)
can be respectively obtained from Eqs. (5. 39)i and (5. 39) 2 . After that, F ( l / ) and
va/) can be determined from Eqs. (5. 49) and (5. 26). In this case, the vector qiir> is
expressed as :
qiW = - μ3 αψ X ι + (SjP + ei/I) X (S?> X R^ + μ, ι) (5. 58)
Substituting it into the condition that the principal relative curvature \Pilf) \2/(yar> ·
af) (/) (1/)
P + n · g ) is equal to kp (see section 5. 4) leads to
| P a / ) | 2 - kjy™ · P ( 1 / ) + (5y> + *>fl f5>l> X Ä> 1) ,n (/) ) ]

A<3= (5.59)
kpa)fnyy
Finally, by expansion of Eq. (5. 56) in accordance with the component of 1 , we have
(Sy> ,£?>,?) + μ3 - v™ - »,ÄÄ>

X = (5. 60)
ω/cos yf
The calculations of other setting parameters are similar to those mentioned above,
and not discussed again.
The setting parameters for machining the concave side (drive side) of a pinion are
calculated to demonstrate the algorithms presented in this chapter. In the engage-
ment coordinates, the required geometric parameters of the tooth surface up to the
second order are:
5 = 0 . 56789 7 — 0 . 80953 7—0.14889 Έ

a)
R = 5 . 8047 1 + 151. 4350 ~j - 31.1928 ί
ex = - 0. 47247 1 - 0.17247 J - 0. 86431 I
~ez =0. 67400 t + 0. 56117 7 — 0 . 48042 k
k[» = - 0. 027664 *?> = 0. 0055076
JR =9.13577°
The machine has a modified-roll mechanism, but no cutter-tilt mechanism. The se-
lected parameters are:
<Pr = 13. 6° EP = 32. 83
The forming position of the reference point are calculated at first. From Eq. (5. 9)
we have
Of =0.56068
Vf =0.14700
Wf=- 0.10661
Then from Eqs. (5. 8) and (5. 7) ,
e = 175. 9073°
- 0. 99745 0 0. 07137 "

Φ = -0.01133 0.98731 -0.15837
- 0. 07046 - 0.15877 - 0. 98480.
Subsequently, from Eqs. (5. 6) and (5. 10)»
n = - 0. 57707 1 - 0. 78211 7 + 0. 23514 k

Ra) = - 8 . 0161 1 + 154. 3882 7 + 6. 2655 k
el» = 0 . 40958 t - 0. 02805 7 + 0 . 91884 k
e?> = - 0 . 70657 1 + 0. 62250 7 + 0. 33652 k
Following this, the generating and difference surface are calculated as follows : from
Eqs. (5.11) and (5.12),
~e\n = - 0. 80468 ~i + 0. 59371 7

~e[n =0.13961 1 + 0.18921 7 + 0 . 97196 k
From Eqs. (5.16), (5.17) and (5.18),
£#> = - o . 023687 , n;1/) = 0. 010775 , * α > = - 1 . 5236* - 4

From Eqs. (5. 19) , (5. 20) , (5. 23) and (5. 24) ,
kf = 6. 4322* - 3 , Θ = 65. 5405% kp=- 0. 028588

R = 151.1077, hm = S. 2655, RP = 149. 5919
The unit vectors of the principal directions of the difference surface are obtained
fromEq. (5.25):
?i =— 0. 67466 i + 0. 61877 7 + 0 . 40244 k

t2 =- 0. 46025 ΐ + 0. 07359 J - 0. 88473 I
Finally, the machine setting parameters are calculated. From Eqs. (5. 28) and (5.
27),
a}1* = 0 . 987315 Ί - 0.158775 7

v^ =30. 69896 ι + 1. 27275 7 + 7 . 91441 k
From Eqs. (5. 34) , (5. 46) and (5. 39),
Gx = 0, G2 = 8.14273
G3 = 6. 6178* - 3, G4 = 0. 24090
Λ2 = - 11. 6986, Mi = G2= 8.1427
o y = 0.16348, X = 31.5421
Then from Eqs. (5.26), (5.50), (5.29) and (5.51),
vilf) =10. 5504 ι - 5. 4049 7 + 7 . 9144 k

pa/> = _ o. 29639 1 + 0. 04739 J - 0. 56975 £
S ( / ) =20.1486? + 6.6776 7
<of =— 2. 0471* — 4
From Eqs. (5.40), (5.41), (5. 42) and (5. 45),
T =89. 7145 ? + 121. 5929 j + 6. 2655 k

V =130.5606 , H = 1.6533
V =130.5606 , H = 1.6533
SP = 130. 5711
q = 89. 2745°
XBP = 5. 0081
The results presented here have been verified by those from the third-order contact
analysis, T C A and cutting experiment, presented in Chapter 1 and 3.
5.8 CONCLUSION
Some algorithms to determine the setting parameters for machining the pinion tooth
surface of spiral bevel and hypoid gears are developed in this chapter. They are sim-
ple, effective, and moreover, they can make a better use of available equipment. For
each kind of method, the blade pressure angle can be freely chosen. If the machine
has a cutter-tilt mechanism, both vertical and horizontal tilt angles can be freely cho-
sen. For the machine having either a modified-roll mechanism or workhead-vertical-
feed mechanism, the value of blank offset can be freely chosen. In comparison,
Gleason Calculating Instructions for machines with cutter-tilt mechanisms only allow
the axial tilt to be freely chosen, while the normal tilt is determined by the pressure
angle of the blade. Although the freely-chosen setting parameters are redundant
freedoms for ensuring the second-order geometric parameters of the pinion tooth sur-
face, they are required in optimal synthesis. Generally speaking, the more the free-
doms are available, the better are the results that can be expected to be found.
Sometimes the increased freedom can enlarge the machining area of an equipment.
For example, by means of the new method, pinion tooth surfaces of Formate hypoid
gears can be machined on a generator with neither cutter-tilt nor modified-roll me-
chanism. This feature is impossible when Gleason method is adapted.
6
An Optimal Synthesis of Spiral Bevel

and Hypoid Gears
6.1 INTRODUCTION
Spiral bevel and hypoid gears with Gleason gearings are used in many applications,
such as helicopters and the rear axle differential box for land vehicles. Generally,
these gears utilize the technique of combined mismatching, i. e. the angular velocity
ratio changes in the process of meshing, and the tooth surface contact is a point if
the load is equal to zero. Many efforts have been made to-date to reduce the kine-
matic errors and improve the contact situations of these kinds of gears. The most
widely used method is the T C A method developed by Gleason Works1-1-1. By means of
simulating the meshing process, a set of better machine setting parameters can be
chosen by the user. These are time consuming, and the results require a further
analysis in terms of parameters or subjective judgement of the user. In recent years
Litvin and his colleagues have developed a method of machining conjugate spiral be
vel gears1-4'5-1, but it cannot yet be used for machining hypoid gears, nor can it ensure
comprehensive contact situations.
OPTIMAL SYNTHESIS 135
As it is k n o w n , high speed and heavy duty gears are generally modified and crowned
to deliver a better contact performance and reduce the vibration caused by the change
of contact rigidity in the meshing process. The authors believe that if the mismatch
amount of these gears can be strictly controlled, it can serve the purpose of modifica-
tion and crowning. In order to achieve t h i s , several steps are needed: i) directly con-
trolling , as many as possible, contact parameters according to anticipated contact sit-
uations ; ii) those that cannot be directly controlled need to be analysed in terms of
parameter, iii) optimal synthesis for controlling the contact parameters which cannot
be directly controlled1-14-1.
The influences of the first and second order contact parameters on the performance
of a gear pair are well known. From the example calculation presented in Chapter 1
and 3 it is known that third order contact parameters also have important influences
on the performance. The analyses of third-order contact situations of combined mis-
matched tooth surfaces, i.e. the rates of change of second order contact parameters
under either running process or V and H check, a direct method to ensure anticipated
second-order contact situations, and the relevant algorithms have been discussed in
the first five chapters of this book. From Chapter 5 it is known that some cutter and
machine setting parameters can be freely chosen for the purpose of ensuring the first
and second order geometric parameters of the pinion flank. The aim of the present
chapter is to develop a method to make use of these freedoms to improve on the
third-order contact characteristics. In order that this method can be used in practice,
this chapter deals also with the presetting of anticipated first-order contact parame-
ters (the position of the centre point of the contact pattern) and the reasonable pre-
determination of second-order contact parameters.
Aa
Σ
\ r— M
V^^^^ Fig. 6.1 The reference cone and

reference point of gear flank
The reason as to why the third-order contact parameters are controlled by means of
optimization is that for most available machine tools, the residual freedoms after en-
suring the anticipated first and second order parameters are not sufficient to control
them directly, unless a generator with both cutter-tilt mechanism and modified-roll
or work-head-vertical-feed mechanism is used. However, machines with these facili-
ties have not yet been widely used in practice.
6. 2 THE REFERENCE POINT ON GENERATING AND GEAR TOOTH

FLANK
The influences of the position of the centre point of contact pattern on the perfor-
mance of a gear pair is well known. But the contact centre is fixed in the Calculation
Instructions developed by Gleason Works. Moreover, since the imaginary tooth sur-
face is used in the calculation and most gear pairs are X-gears, the position of the
original contact centre is generally unreasonable, and many trials are needed to move
it to a suitable position.
In this book the position of the reference point is expressed as follows · suppose the
reference point on gear flank Σ < 2 ) is M (see Fig. 6. 1 ) ; through M make a circular
cone parallel to the root cone of the gear, which is named reference cone 2 G Ä . T w o
parameters, the reference cone distance AG and the vertical distance bG between Σ σ *
and Σ Α > are used to characterize the position of the reference point. They can be
chosen in accordance with the desired position of the centre point of contact.
Fig. 6. 2 is an illustration of the machining of gear flank. Where Oc is the machine

centre, P is the mean point of gear face, and 0GK the mean root cone spiral angle. N
— AT denotes the cutter tilt plane. If cutter-tilt mechanism is used, the cutter turns
an angle / about P in N — N. Through P make a line perpendicular to the axis of the
c u t t e r , the intersecting point being CT* Denote the position vector OcCT by CTy the
unit vector of the axis of the cutter by Q. In the original position, they can be respec-
tively expressed as
CT = (R0 cos / cos (pGR + EG)1 + (Ly — RQ cos / sin (pGR)J + (bQ + R0 sin I)k
(6.1)
Q = — sin / cos <pGR i + sin I sin <fiGR j + cos / k (6. 2)

Fig. 6. 2 An illustration of machining the gear flank
where R0 is the mean cutter point radius of the alternate blade cutter for finishing the
member gear, EG is the member gear blank offset,
Ly = A cos dG + CG cos Γκ — XBG cotan Γκ (6. 3)
b0 = A sin dG — CG sin Γκ (6.4)

in which A is the mean pitch cone distance of the gear, dG the dedendum angle of the
gear, C G the gear root apex beyond the pitch cone apex, r ^ t h e root angle of the gear,
and XBG the slinding base retreat.
Let a and b denote two unit vectors perpendicular to Q. a is in the cutter-tilt plane N
— N, while b is perpendicular to N — N,
a = — cos / cos <pGR i + cos / sin <f>GR j — sin / k (6. 5)
b = sin (JJGR 1 + cos <pGR J (6. 6)
For a certain point M' on the generating flank formed by the rotation of cutting
edges, its position vector can be expressed a s :
X =CT+ (5 =F r cotan <fc) Q + r (cos Θ a + sin Θ b) (6. 7)
where r a n d Θ are two parameters, and the upper sign in "=(=" or " ± " is for the con-
vex side of the gear, the lower for the concave side,
I W\
s = ± #o — γ cotan <fc — b0 (6. 8)
The unit normal at this point is
n = =F (cos Θ ä + sin Θ 6 ) cos (fa — sin (fc Q (6. 9)
Suppose the cradle needs to turn an angle ^(C> to carry this point into contact with the
gear tooth surface. After the rotation, the position vector and unit normal can be re-
spectively expressed a s :
Rp =χχ c o s φ(θ _ Xy s i n φ(ο ^

R^ =XX sin 
+ Xy cos ? (C)
(6.10)
nxC) =nx cos ^ C ) — ny sin <p(C)

nyn =nx sin qfc* + ny cos ^ C ) (6.11)
c
n< > = n r
The position vector on the tooth surface formed by above mentioned point on the
generating flank will take the form:
£«> = £<C> _ L (6.12)
where
L = EGi — XBG cotan Γκ j (6.13)
The velocities of both generating and generated flanks at the point are expressed, re-
spectively, as follows:
-<C> -(C) £<C>

= χ
(6.14)
ϊ<2> = Uzca™ X R™ (6.15)
where w2c is the ratio of roll of the generator,
<z(C) = - k (6.16)
a<2) = cos Γκ j — sin Γκ k (6.17)
are the unit vectors of the axes about which the generating and generated surfaces
rotate. Now the unknown turning angle <jfC) should be determined. From the engage-
ment equation
«<c> · (ϋ< 2> - S ( C >) = 0
it is known that
n(C> · [w 2 C ä ( 2 ) X (£< c> - L ) - 5(C> X #< c >] = 0

Substituting above equations into this o n e , and after simplification, we have
(1 - u2C sin Γκ) («, Xx - nx Xy) + ulc\_iXz + X 5 G ) ( n , cos ? (C)

+ ny sin 9?(C)) cos Γκ + 2£G(ny cos 9?(C) — nx sin 9^c>) sin Γ Λ
+ nz( EG - Xx cos φ{€) - Xy sin ^ <C) ) cos Γ Α ] = 0
This equation can be written in the form :
Uc sin <ffC) + ^ c cos ^ (C) = Wc (6. 18)
where
Uc = u2C[ny(Xz + ^ 5 G ) COS Γκ — Ec nx sin Γκ — X, nz cos i /? ] (6.19)
Vc = u2C\_nx{Xz + XBG) COS rR + £ G ny sin Γκ - Xx nz cos Γ Α ] (6. 20)
V^c = ( "2C sin Γ Λ — 1) (jiy Xx — nx Xy) — u2C EG nz sin Γκ (6. 21)
The solution of Eq. (6. 18) is
Wr Vr
Wc
ψν = t a n - 1 - tan"1;/ (6. 22)
Uc
%/Uc + Vc - Wc
Thus the position vector of point M on the generating flank S ( C ) can be determined
by substituting the value obtained into Eq. (6. 10). Then the position vector of the
mating point on gear tooth surface Σ ( 2 ) can be determined by Eq. (6. 12).
Through point M' we can also make a cone parallel to the root cone. The cone dis-
tance and the vertical distance between the two cones a r e :
[ä (2) x i? ( 2 ) '
Ac1 = ' _,.;V V ' (6. 23)
sin rR
bG> = (AG' cos Γκ - a(2> · # < 2 ) ) sin Γκ (6. 24)
By means of Newton's iteration method, we can gradually reduce the distance be-
tween ( AG, bG ) and ( AG', bG' ) to less than a preset positive number ε , which
means the generating position of the reference point and the generating point on Σ ( °
are determined. Then the second and third order parameters of gear tooth flank at M
can be calculated by means of the algorithm presented in Chapter 2.
For a Formate gear pair, the angle of rotation of the cradle need not be calculated.
Set RiC) = X , and then calculate r a n d Θ by means of Newton's iteration method.
X \
Fig. 6. 3 Fig. 6. 4
Fig. 6.5
Fig. 6. 6 Fig. 6.7

Motion Curve for Contact
at Mean Point
Φ"
Gear Lag

Moved Towards Inside of Blank
ψ"
Gear Lag

Moved Towards Outside of Blank
Gear Lag
Change in Curvature of Motion Curve Along Face
Fig. 6.8
6. 3 THE OBJECTIVE FUNCTION FOR OPTIMAL SYNTHESIS
In order that the optimal synthesis of machine setting parameters can be automatical-
ly accomplished on a computer without the subjective judgement of the user, a rea-
sonable objective function needs to be established. Since the second-order contact pa-
rameters are preset and directly obtained, they are not involved in the objective func-
tion. Now the dilemma concerns which third-order contact parameters should be
considered. According to some experts, the third order contact situations can be
characterised by six parameters: the amount of the projection of the contact point
path(CPP) on the tangent plane deviating from the tangent line (Fig. 6. 3 ) ; the
change of the lengths of the instantaneous contact ellipses when the contact moves
from the top to the root (Fig. 6. 4 ) ; the asymmetric amount of the curve of the an-
gular speed ratio in one pitch arc (Fig. 6. 5 ) ; and when the contact pattern moves
from the heel to the toe under V and H check, the changing amounts of the direction
of CPP (Fig. 6. 6 ) , the lengths of contact ellipses (Fig. 6. 7 ) , and the gear lag in
one pitch arc (Fig. 6. 8 ) . From differential geometry point of view, these parame-
ters are the rates of change of three second-order contact parameters, which are pre-
set to characterize anticipated second order contact situation, in the running process,
and under V and H check when the centre point of contact moves along the longitudi-
nal line of the tooth surface.
As it is known, for a point on the pinion tooth surface, there is only four indepen-
dent third order geometric parameters. Six third-order contact parameters mentioned
above are determined by these four parameters. Thus the six parameters are not in-
dependent of each other and two of them can be linearly expressed by the other four.
However, the expressions are complicated, the degrees of correlations among them
depend heavily on the choice of the second order contact parameters, and it is diffi-
cult to identify the one which is more important. Therefore the authors feel that the
objective function should rather involve all the six parameters.
In order that the machine setting parameters found from the program can be realized
on a certain generator, a penalty function should also be involved in the objective
function. Thus the final form is:
Begin, — 1- K
Read Original Parameters
Calculate cT, Q , a and b

I
Set r 0 , θ0
Use Newton
No Iteration to
2
y/WG - AGY + WG ~ M ) < e
[Calculate r
Yes and Θ
- 1
K =?
£ 1
Calculate Geometric Calculate Geometric
Parameters of Inner Parameters of outer
Generating Flank Σ (ο) Generating Flank Σ (ο)
Yes No
Is the Gear Formate?
_L
Parameters of Σ (( Calculate Parameters of Σ (
Calculate Second Order Parameters of Pinion Tooth

Surface According to Anticipated Contact Situation
i 1 —L
Set Original Freely-Chosen 3

Setting parameters
f.{L)
MVIMH* -*- VH and # L ) - » φρ9 Step tp9 Accuracy ερ
[Calculate Cutter and Machine Setting Parameters
Calculate Third Order Geometric Parameters of Pinion Flank
Calculate Third Order Contact Parameters

I No Optimizing μν^Η and
Optimal Synthesis Finished?
<PP by Means of Direct
TYeT Search
L+ l^L
No
L>N
I
lYes
Compare F{L) to Get F{P\ F(/>)<F(L), L = 1 - N
I
Print Setting and Contact Parameters of Group P
No I
K X = 1
£Yes
End
Fig. 6. 9 The process of optimal synthesis for machines with cutter-tilt mechanism
J, |F1-^F,F1-*F2, x-+x{ No
m \xX + AXtp - » XX , 1 ~» J F2<F
JL
Yes \x-+xa\3
\x2 + A2tp- ' Xz 9 F2-*F
IYes
Calculate Cutter Fl —F2 2xa) - xi0) ΧΔ

land Machine Set-| F K F 2 X ~*" Xo 9
ting Parameters IHö" \X\ CitA\tp —^ X\ 9 — 1 -+m9
T \xx + A\tp - » xx
Calculate Third
Order Parameters Yes \X\ ^ Λ» *ö ^ t/ » No
lof Pinion Flank «^2 i A2 ^^ ~"*" «^2 9 m = - 1
i FI-+F2 Yes
Third Order Con- FKF2
tact Analysis No \Xi + Aitp •3^1 » x v w -*► x
Yes— 1 3— 7 \xi + Ajp-^x,
|^2 I A2tp ~* &Z 0-*m
No
Yes \X ^ «2? 9 O ^ «/ ♦ \tp/10 **K
[Calculate Objec-
tive Function F l Fl — F2 Yes
F1<F2 \tp < *P
</=? \ML \Xz u^z^p ~*" ^z 9 No
4-+J
L + l
Yes \X ^* X f 0 ^ «/ f
x"' -*> a:
\x3 + A3tp -*> xz
F\-*F2
FKF2 X9 1 • ra
No Xz T" ^ » 2 ^ ~ ^ «^2 ♦
Xi -\- A$tp —*■ Xi
No \x% — 2Aztp ' X$9
FKF2
Yes
\ F1-*F2
Yes
» - H F l < F2 \ F1-^F2
[No
Fig. 6.10 Illustration of direct search method

x = Ov> μ*> 0ρ)> *<0> = (/Vot /%o> ψρ*)
Begin» — 1 K
Read Original Parameters
Calculate cT> Qâ and b

I
Set r 0 , 0O
Use Newton
No Iteration to
JM'G - AGy + (*'c - bGy) <. [Calculate r
Yes and Θ
X =?
X 1
[Calculate Geometric Calculate Geometric
Parameters of Inner Parameters of outer
[Generating Flank Σ<€) Generating Flank Σ(ο>
Yes No
Is the Gear Formate?
Parameters of Σ(< Calculate Parameters of Σ<2)
Calculate Second Order Parameters of Pinion Tooth]

[Surface According to Anticipated Contact Situation
I
1— L
5
Set Original Freely-Chosen Setting parameters
ra> EP and tfpL) -»» <pP9Step tp9 Accuracy ερ
Calculate Cutter and Machine Setting Parameters

t
Calculate Third Order Geometric Parameters of Pinion Flank
X
Calculate Third Order Contact Parameters
I No [Optimizing EP and J
JL
Optimal Synthesis Finished?
<PP by Means of Direct
TYe7 Search
No I
L>N
TYes
Compare Fa) to Get FiP), iP)
F < F(L), L = 1 - JV
I
Print Setting and Contact Parameters of Group P
No I
ι-»κμ K = 1
End
Fig. 6. 11 The process of optimal synthesis
for machines with modified-roll mechanism
■J, Fl — F , Fl — F 2 , x-+xa)
F2<F
-£ No
m xx + Axtp — xx, 1 — J
Yes
.3? ^* X » d ^* t/ ♦
Yes
_L \Xz I ^2 ^ """*' ^ 2 * F2 — F
Calculate Cutter F l — F2 2* (1> - * ( 0 ) — x9
and Machine Set- F K F 2 X "*" XQ »
ting Parameters ΓΝο^ \xx — 2Δγίρ ■ ' X\ i — l-*»m,
T 2— / xx + A^ "** x\
Calculate Third
Order Parameters Yes
>
~' X * d ""*■ */ » X No
of Pinion Flank jΛΓ2 l ^ 2 tp ~~*" 3*2 » m =— 1
I
[Third Order Con- FKFZ
Fl —F2 Yes
tact Analysis No LC! + Δ ^ — XX ,

L 3 —J xx + Δχί^ — x,
Yes ■—
m = 1 ^2 I *^2^p ~ " 3*2
>
0 —m
No
No \Xz Z^tp —** Xz\ |^/10 — ^
Calculate Objec-
tive Function F l FKF2 Yes
Yes vw
r , <^ *, ~
J =Ί \x — .r , No
Fl — F 2 ,
\L + \ Yes |wC ^ X 9 lx <0> — a; 1
Fl — F 2 , |;e, + A^tp -»· Xj |
w
F K F 2
No * <0> -— x , 1 — m
Fig. 6. 12 Illustration of direct search method

x = ( F P , #>), x ( 0 ) = ( F P o t ^ o )
d 2 d
JT ^M-L ( M . / V2) I2 ■ Ι ά υ
\\ [άιΑζ
+ w
'[d?"( ( α ^ ψ ) ] 2 + (£m
" - Δ, - FP - |F_ - AE - EP |)«
2
+ (F min + Δ Ε - EP + |F min + Δ Ε - EP \)
+ 100 (?u* — Δ , — 9* — IfU» - Δ, - ΨΡ \Y
+ 100 ( f e n + Δ , - 0P + \<Pmin + A9 - ψρ I ) 2 (6.25)
for the generator without cutter-tilt mechanism, and
FT = F + 100 0 m a x - Δ,· ~ i ~ | w - Δ, - ί |)2 (6.26)
for the generator with cutter-tilt mechanism, where G (2) denotes the geodetic curva-
ture of CPP on the gear flank Σ ( 2 ) > ^ t h e length of the instantaneous contact ellipse,
5(2> the arc length of CPP on Σ ( 2 ) » <Pa) and 9<2) the angles of rotation of the pinion and
gear, othe angle between the directions of CPP and profile on gear flank, s* the arc
length of the longitudinal line of the gear flank, wt- the corresponding weights, Em&x
and £ m i n the maximum and minimum of blank offsets (mm) , feaxand fen the maximum
and minimum of the cutter pressure angles, and im&x the maximum cutter tilt angle.
Fig. 6.13 The direction

of CPP on gear flank
6. 4 O P T I M A L SYNTHESIS PROCESS
The basic process of optimal synthesis for the generators with cutter-tilt mechanism,
but without modified-roll mechanism, is illustrated in Fig. 6. 9. In order to reduce
the possibility of missing the best point, a direct search begins from different points
in the space of freely-chosen parameters. For each parameter, two original values
are chosen. So in this case, N = 8. The final result is automatically selected from
the eight groups. If one parameter should be kept unchanged, e. g. the pressure an-
gle of the cutter so that an available cutter can be used, set the maximum and mini-
mum of this parameter to be the same value. The system will automatically delete
the corresponding freedom. Detailed direct search method used in this program is il-
lustrated in Fig. 6. 10.
The optimal synthesis process for generators with modified-roll, but without cutter-
tilt mechanism, is illustrated in Fig. 6. 1 1 , In this case there are two parameters
which can be freely chosen. Therefore, N = 4. Detailed direct search method used in
this program is illustrated in Fig. 6. 12.
6. 5 REASONABLE P R E S E T T I N G O F C O N T A C T P A R A M E T E R S
A direct method for determining the second-order parameters of the mating tooth
surface according to predetermined contact situations has been presented in Chapter
4 , but the problem concerning reasonable presetting of the second-order contact pa-
rameters is still left to be solved. The three preset parameters are · the directed angle
between the tangent of CPP on gear flank and the profile direction υ (Fig. 6 . 1 3 ) ; the
projection length of the instantaneous contact ellipse on the longitudinal direction of
gear flank B ; and the angular acceleration of the gear relative to the pinion dy 2)
(d?a>)2·
B is generally chosen to be 0. 4 — 0. 5 of the face width of the member gear, while

dV 2 )
( , (1),2 can be determined by the required amount of modification. For general pur-
poses, it can be chosen from Table 6. 1. It should be pointed out that this parameter
Table 6. 1 Suggested Angular Acceleration

of the Gear Relative to the Pinion
Pinion tooth number 6 8 >10
2 (1) 2
d y 7 (d? ) 0.0004-0.0005 0.0006-0.0008 0.0012-0.005
should be negative for the drive side, and positive for the reverse side, because the
assumed turning direction of the pinion is one and the same for both sides in calcula-
tion process. However, for the choice of u, there are some very different opinions.
The Gleason Works always chooses the direction of CPP to be along the profile of
the gear tooth flank. Litvin points out that the direction of CPP shoule be along the
longitudinal direction of the gear flank to get a better lubrication condition1-5-1. The
present authors feel however that more factors have to be considered. Here a numer-
ical example is presented to illustrate the influences of f on other contact situations.
The example conserns the drive side of a pair of hypoid gears. The basic parameters
of the gear pair have been presented in Chapter 1.
Table 6. 2 The Influences of the Direction

of CPP on V and H Displacing Rates *
υ 0° -10° -20° -30° -40° -50° -60° -70° -80° -90°
dV/ds- -42.1 -39.8 -37.7 -35.5 -33.1 -30.4 -27.0 -22.2 -14.9 -1.27
dH/ds' 61.6 54.4 47.9 41.7 35.6 29.2 22.3 14.8 8.09 14.4
* d V 2 > / (d^ ( 1 ) ) 2 = — 0 . 0004, the unit of displacement is 0. 001 mm
Table 6. 2 shows the influences of o on the displacing rates between gear axes in V
and H directions with respect to the moving distance of the centre point of the con-
tact pattern along the longitudinal line of the gear tooth surface 5* when the gear pair
is under V and H check.
Table 6. 3 shows the influences of (, (1).2 on above-mentioned parameters. From
Table 6. 2 it is known that the displacing rates are greatly reduced if CPP is along the
Table 6. 3 The Influences of the Relative Angular Acceleration

on V and H Displacing Rates (0. 001 mm)
dy27(dp(1))2 -0.0008 -0.0012 -0.0016
υ 0° -50° -90° 0° -50° -90° 0° -50° -90°
dV/ds* -42.4 -31.0 -2.51 -42.7 -31.6 -3.71 -43.1 -32.2 -4.87
dH/ds· 74. 2 42. 9 28. 3 86.4 56.3 41.8 98. 2 69. 2 54. 9
longitudinal direction of gear flank. As a result, the sensitivity of the contact perfor-
mance to the misalignments is increased. From Table 6. 3 it is known that unless the
amount of modification is greatly increased, the sensitivity cannot be reduced. How-
ever, this method will lead to unacceptable kinematic errors.
Table 6. 4 shows the influence of υ on the relative rolling velocity beween tooth sur-
faces νΣ , as well as its projection on the minor axis of the instantaneous contact
Table 6. 4 The Influence of the Direction of CPP

on the Lubrication Condition of the Gears *
υ 0° -10° -20° -30° -40° -50° -60° -70° -80° -90°
ν
Σ 15.87 16.05 16.41 16.96 17.73 18.82 20.44 23.02 27.69 38.11
VEP 15.86 15.85 15.85 15.84 15.82 15.81 15.78 15.73 15.63 15.36
* d y 2 ) / (dp (l) ) 2 = - o. ooo4
ellipse νΣΡ. From these values it is known that although the relative rolling velocity is
very high, if the direction of CPP is along the longitudinal direction, its projection
can hardly be changed. As we k n o w , the width of the contact ellipse is very small in
comparison with its length. So the increment of the componental rolling velocity
along the major axis cannot apparently enhance the load carrying capacity of the oil
film.
Table 6. 5 shows the influences of v on the speed of the contact point moving on the
gear flank, and the theoretical overlap.
Table 6. 5 The Influences of the Direction of CPP on

the Moving Speed of the Contact Point and Overlap *
υ 0° -10° -20° -30° -40° -50° -60° -70° -80° -90°
C2 cl)
ds 7dp 10.52 10.11 10.01 10.23 10.79 11.80 13.46 16.25 21.30 32.35
Overlap 0.94 1.00 1.07 1.15 1.25 1.39 1.62 2.11 2.37 1.51
* d y 2 ) / (dp ( 1 ) ) 2 = - 0. 0004
Although these values are only from one side of one pair of hypoid g e a r s , the basic
rules are true for the others. Above all, the authors believe that a tooth bearing with
a natural bias (bias in) offers a better comprehensive contact performance, and with
value of v chosen between —20° and —60°.
Unless there is some special purpose, the contact situations are desirable not to
change apparently during the meshing process. So the expected values ( E V ) of the
third order contact parameters are easy to preset; these are simply set to zero, as in
Eq. (6.25).
6.6 CONCLUSION
In this chapter a method of presetting the arbitrarily-chosen position of the centre

point of contact pattern, and an outline of optimizing the contact situations of spiral
bevel and hypoid gears using freely-chosen cutter and machine setting parameters are
presented, and the method of reasonably choosing the second order contact parame-
ters is also discussed. A numerical example is given to illustrate the influences of the
direction of CPP on the other contact parameters. From the example some important
conclusions are reached. Other analytical methods and algorithms required in the
process of optimal synthesis have been presented in the first five chapters. Thus the
whole process of analysis and optimal synthesis of the contact situations of spiral
bevel and hypoid gears has been completely presented in detail. The characteristics
of the proposed method are: i) the position of the centre point of gear tooth bearing
can be arbitrarily assigned and preset in accordance with practical requirement; ii)
the second-order contact parameters of the gear pair can be predetermined and kept
unchanged in the optimal synthesis process; iii) since the objective function is com-
posed on the basis of the third-order contact analysis, the program can run automati-
cally without any subjective judgement or intervention being necessary by the user.
Also, accurate result and rapid response can be expected.
7
Analysis of the Error Sensitivity

of the Contact Situations
with Respect to Mounting Errors
7.1 INTRODUCTION
The error tolerance of point-contact tooth surface is generally wider than that of
line-contact tooth surfaces. This is an important reason behind many practical appli-
cations of point-contact tooth surfaces. Although the theoretically conjugate tooth
surfaces can be obtained in some cases, they are modified and crowned to provide a
local contact so that the error-sensitivity can be reduced. In order to achieve even
better r e s u l t s , it is necessary to have quantitative knowledge of the influence of indi-
vidual misalignments, and of the combined result of them. Based on this considera-
tion, a mathematical model is established to describe the responses of contact situa-
tions to the misalignments1-15-1.
In this chapter two matrices concering the sensitivity of the position of tooth bearing
and the second-order contact situations of point-contact tooth surfaces with respect
to the mounting errors are derived by means of analytical method. The former con-
cerns the responses of the position of the contact pattern centre to the mounting er-
rors. The latter is about the responses of the second-order contact parameters, in-
cluding the direction of the contact point path on the gear flank, the length, width
and inclination of the instantaneous contact ellipse, and the derivative of the trans-
mission ratio of gear drive, to the mounting errors. They are not only very impor-
tant for understanding the influence of mounting errors to the contact characteris-
tics, but also they give criteria for reasonable assignment of tolerance for manufac-
turing and assembling, for reasonable choice of geometric parameters of tooth sur-
faces , and for reasonable design of the structure of a transmission device. There are
many more applications but the scope of the present chapter is limited to those afore-
mentioned.
7. 2 MOUNTING ERROR VECTOR OF A GEAR PAIR
In this chapter the mounting errors of a gear pair with non-parallel axes are ex-
pressed in the form of a four-dimensional vector. It is denoted as the mounting error
Fig. 7.1 The relative position between axes

ERROR SENSITIVITY ANALYSIS 155
vector. The situation of two known surfaces in contact at the reference point M i s il-
lustrated in Fig. 1. 1, where α α ) and <z<2) denote the unit vectors of the axes of gears
1 and 2. The angles of rotation are denoted by <pa) and 9?(2>. Ra) and Ri2) are position
vectors from the points fixed to the axes to the contact point. L is the distance from
the point fixed to α α ) to the point fixed to <2<2>. The relative position of the axes is il-
lustrated in Fig. 7. 1. The angle between the axes is denoted by Σ . <z<3) = <2(1> X
a ( 2 ) / s i n 2 is a unit vector perpendicular to both axes. The relative position errors be-
tween the axes are then expressed by three linear movements and a rotation. The
three translations are expressed by the components of the changing amount of L
along the unit vectors α ( ° , and the moving distances are denoted by s{. T h u s their in-
fluence on L can be expressed by
ψ = α«\ ψ = ~α«\ ~ = ä^ (7.1)

d S\ d $2 d S%
The rotational variation is given by the angle when the axis a (2) rotates about α (3) ,
i. e. the increment of Σ · In order that formulae can be written in a unified form, we
set ds 4 = d S . T h u s
a s _ io (i = i, 2, 3)
(7.2)
dSi " [i (,· = 4 )
| ^ = [ ( L , 5< 2 \ a <3) ) cotan Σ - L · α ( 2 ) ] α (2) X a (3) (7. 3)

o 54
The array (asi9 ds2> ds 3 , d54 ) is called the mounting error vector and denoted by
Δ.
7. 3 ERROR S E N S I T I V I T Y M A T R I X OF T H E POSITION O F T O O T H
BEARING C E N T R E
For a pair of combined mismatched tooth surfaces, the conditions for a certain point
being the centre point of tooth bearing a r e : i) that this point can become a contact
with the mating surface, and ii) when this point is in contact, the instantaneous
transmission ratio d^ 2) /d^ (1> is equal to the ratio of tooth numbers of gear 1 and 2 , w2i
£*(£,)
Fig. 7. 2 The principal directions

at the reference point
= n/N . When the gear pair is set in the designed mounting position, the centre
point of tooth bearing coincide with the reference point.
Figure 7. 2 shows the situation of E (1> and Σ ( 2 > in contact at the reference point M ,
where ex and ez denote the unit vectors of principal directions of Σ α > , e3 = ey X e2 is
the unit normal of Σ ( 1 > at M. When the contact point moves along Σ α > > the frame
formed by the three vectors moves in conjunction with it like a rigid body. This
frame is considered as the moving frame of Σ ( 1 ) . Similarly, the unit vectors of the
principal directions and normal of Σ <2> also form a right-handed frame, denominated
as the moving frame on Σ ( 2 > . If the mounting distances are changed, the centre
point of contact moves on the tooth surfaces. In the individual coordinate systems
rigidly connected to the gears, the derivatives of the moving frames with respect to s,·
are as follows·
d e2
SS:
=
~ dΈΤ e V *3
Si i + WTT
(7.4)
dsi
III =_*<!> l 2 a 2
ds{ *l d Si d -Si
d S,· d Sj d 5,·
de2 Q\ - il 2
€χ
x + *ί
2 v «14 -
3 (7.5)
d Si ^5,· " ' " as,·
Ω1 - M2
as, as, aj f .
where i = 1 . . 4 ,
ω2 Ω\
_Zi.
dSi
— Λ<1)_
d Si
L Λ<1)-_
a Si
_-±-
as, P\' d Si
+ pi' a Si
(7.6)
£ j n and kf> denote the principal curvatures of Σ α > and Σ <2> at M , p)l) and /oj2> the
geodetic curvatures of the lines of curvature, whilst ω' and ß'are the projections of
differential moving distances of the contact centre along tooth surfaces on frame ax-
es. In the fixed coordinates, the derivatives of moving frames can be expressed as
follows :
a Si a Si d Si
(7.7)
d Si d Si d Si
(7.8)
ψ Jh. + if. 5«> x i3 (7.9)

d Si a Si a s{
_a_ei , a
| i ; =£li + ^ 5«> x έι + | Σ -<3, x -ει (7.10)
a s,
d Si a s,
d Si d Si a Si
(7.11)
(7.12)
The position vectors from the points connected to the axes to the contact centre are
denoted by Ray and Ri2) in the fixed coordinates. The partial derivatives of them with
respect to s, will be
+ C7,13)
as, ~ 3 s, ei 3st e* + ds, α XK
if™ = §L ί, + φ. l2 + *ί! 5«> x Λ«> + ψ- 5«> X *<*> (7.14)

d Si d Si d Si d Si d 5,·
From Fig. 1. 1 it is known that the conditions for tooth surfaces in contact can be ex-
pressed a s :
JR = Ä<2> + Z
e = e
Z 3
For keeping the tooth surfaces in contact after the relative movement between the
axes, the first condition becomes
dRa) dR(2) , dL
(7
-Js7 = ^s- +
dS-i ·15)
Substitute Eqs. ( 7 . 1 3 ) and ( 7 . 1 4 ) into this equation,
d Si d S{ d Si d Si
5<2)
= ΊΓ1Ι + ΪΓ^ + *-ΊΓ x *<2) + Ψ- *(3> x *(2>
d Si d Si d Si d Si
Then make scalar product separately with e\, e2 and e3. Taking ez = e3 into account
and setting n = e3 = e3 , three equations can be obtained as follows ·
Ω1 Z1 S2 . d <gl·» _ - _
C0S + Sin (e 6l)
dir dl * dii * + dsT ·R '
(α (1 >, * « \ η ) ^ - (α< 2 \ * < 2 \ n ) ^ - = ψ(α»\ i?< 2) ,«) + ψ · η

a Si d S{ d Si d 5,·
where ψ denotes the directed angle for ex rotating to εχ in a counterclockwise direction

about n . The third equation can be expressed as
c + C = C15 (7 18)
"ds~ "~fs~ ' ·
wher
c[3 = (a«>, Rw , n ) , c' u = - (a<2>, #<2> ,n) ,
c\s = ^4J.
^ ( arZii)
( 3 D<2)2) ,n)
\ i?< Z-» +
_i_ ^? L=· ·. n~ (7. 19)
<7 5,· σ Jf·
To keep the tooth surfaces in contact after the relative movement between the a x e s ,
the second condition for the surfaces in contact will become
d ez _ d ε3
d Si d Si
Substitute Eqs. (7. 9 ) . (7. 1 2 ) , (7. 4) and (7. 5) into this equation,
- k"fl ^ - *?ln *2 + ΤΓ 5<1> x «

d Si d Si d Si
= - *i 2 > £ «i - * ? } S *> + 1 Γ Γ «<2> X ** + I ? 5<3> X έ.

σ 5,· d Si d Si d Si
Separately making scalar product with εχ and ε2 leads to
- k?>£- cos ψ - k^sm Ψ+ ^ α(1> · έ2

d Si d Si d Si
- * l a*, +
35,- a ε
* +
ai;a 62
d ( 1>
1.(1) ^ ' / L(l) ^ I ^ "(I) "
k[iy— sin ψ — k\u^— cos ψ ^-— α α ) · sx
a 5,· d S{ d 5,·
<7 5,· σ 5,· <7 5(·
Substitute Eqs. (7. 16) and (7.17) into these equations, we have
- k[l>£- cos ψ - k?>£- sin ψ + d-f^~ i (1> · i«

d Si d S,· d Sj
= - k<M~ cos φ + g- sin φ + ^ ( 5«>, *«>, ί,) - ^ ( 5«>, R«\ iO

Ld Si d Si d Si d 5,·
- Ά S«\ *«>, ίι) - | ^ · ill + ^ 5<2» · ί, + ψ 5«> · i,

d Si dS{ J 9s, 3S;
Ai»!^ sin I - * J » | j cos ψ - ^ 5<l> . i,
= - * H " - | ^ sin φ + f- cos ^ + ^ ( 5<», Ä « \ έ2) - ^ ( 5<», Ä«>, e2)

L d Si d Si d S{ d Si
- g ( S«>, K<2>, e2) - f | . i j - ^ ?» . i, - f £ *» . et
These equations can be written in the form:
+ c 24
^ + ^υ, + '»-£r ' ^r = ck (7 20)
·
. Z1 . Z2 . d$fu . d<ff2>
C 33 +
η
' Έ7, +
^JJ, +
' "^T ' ~ds~ = cU
c 3i (7,21)
where
4i = (*i2> - *ί η ) cos (» , c22 = (*«> - *J»>) sin f»,
c'23 =5(1> · i 2 4- AP><5 a \ *<», O , C24 = - * i » ( S « \ Ä«>, ij) - 5<2> . e,
4s = f ^ [ 5«> · i, + *i»6«>, i?<2>, e,)] + * { » | ^ . i, (7. 22)

σ Si d S,·
4i = ( * { " - *?>) sin f», c'32 = (A<2> - £<») cos ψ,

4 3 = - αα> · et + A£2) (5 <l> , Λ α > , ί , ) , c'3t = - kP (ä(2>, Ä<2), i t ) + ä<2) · ix
4 5 = | S [ - 5«> . Ϊ, + k?\a«\ i?< 2 \ i 2 ) ] + ^ 2 > | ^ . i , (7. 23)
From Chapter 1 it is known that the instantaneous transmission ratio of the gear pair
can be expressed a s :
d<z>a) _
-
For the centre point of the contact p a t t e r n , the transmission ratio should be equal to
the ratio of pinion tooth number to gear tooth n u m b e r , i. e.
(5(1>,Ä(1),i"s) n
w
Z = M = 2i (7. 24)
(2 2
( a \ #< >, έ 3 )
In order that the transmission ratio at new contact centre is still equal to the ratio of
tooth n u m b e r s , this equation should be valid after the movement of the contact cen-
tre on the tooth surfaces. T h u s we have
d Si d Si
= «2i (7. 25)
2 3 2
ä< > + ä< > X α< > ψ- ds,·, R™ + ^ dsi9h + | ^ dSi
d Si d Si d Si
This equation can be written a s :
Ga\ Rw, e3) + ( s a \ ^ d5,·, e3)+ (ä(1\ # ( 1 \ f f di,
\ d Si d Si
= "21 (ä< 2 \ R<2\ i 3 ) + |* ( 3 ) X a(2> | y dsif Ri2\ ~ε3
, ,- a #<2) , - I , | - 3 ) ^ - (<2) aE i dRa) -

+ a(i22\) —— ds,, e3 + a((3) X a 2 ) -f± ds,, —— A
ds,, ε,
a Si I \ d Si d Si
+ (s<2\ Ä«>,|^ dJ + (s«> X S<2> f £ di(., R<*\ | ί ϊ dJ

\ σ 5f· / \ d 5,· a Si )
. i-(2) 3 ^ ( 2 > d5J ^ έ3 d5 \ /α χ α

- 9Σ A d&*>d A5 di3 d5 \
+ \\a ' ~Ξ~Γ~
d 5f· <> ^~T
d 5,· ' / + \ ^dΤSid5»'»"äT"
d 5,· " T d~ 5,· « /
Compare this equation to the original one, and neglect the terms containing dsf and
dsf , it becomes
a , *£-dst,it\ + 5«\*<»>,pd5,
a Si I \ d S{ I
«21 "(3) χ -<2) ψ aSiy R<»f -) + (ä<2>, d-§^~ dsi9 i 8 | + (α<2>,*<2>, Ι ^ dSi)
d Si I \ dSi J \ 3 Si I
After Substituting Eqs. (7. 9) and (7. 4) into this equation and simplification, an-
other linear equation is obtained:
. ω1 , . ω2 , . 3φι)
( 7
C
«dJi+C«3i,.+C«-3l- = C
« ·26)
where
eil = *!" 5<21> ' ex + ω<21> · ~ez, c\z = *|° ü<21) · e2 - ω<21> . e l t
<4 = (ω(21> X n) · (S a> X Äa>) + Qa\vm\n) ,
4 = " n [ | ^ ( ä ( 3 ) X 5<2>) · Ö?<2> X n) - ( « ( 2 \ § ^ , n) ] (7. 27)
in which
ü<21> = u2l ä(2) - 5 ( 1 ) , i (21) = w21ä(2) X # ( 2 ) - ä(1) X # ( 1 ) (7. 28)
Therefore, for each value of index i , a set of four linear equations (7. 18), (7. 20),
(7. 21) and (7. 26) is established. For a given value of i, -r—, r— , ^ and ^ can
dS,· 3 5,· d Si d Si
Ω1 Ω2
be determined by using this set of equations together. Then the values of ^— and ττ—
d Si d Si
can be obtained from Eqs. (7. 16) and (7. 17). It is clear thatc^(> = 1. . 4, k = 1..
4) are independent of index i , so they only need to be calculated once. After the in-
dex changes step by step from 1 to 4 , a 4 X 4 matrix is obtained:
ω1 ωζ Ω1 Ωζ
d Si o S\ o Si o Si
l 2 1
Z Z Ω Ω2
d S<£ d S2 d S2 d S2
*1 = (7.29)
JJ_ ω^_ &_ Ω*_
α?_ ω*_ &_ Ω*_

d S± d S4 d Si d 5 4J
From the multiplication of the mounting error vector Δ with this m a t r i x , the moving
distances of the centre point of contact on pinion and gear tooth surfaces are deter-
mined. This matrix can map the mounting errors into the contact-centre position
space. This is called the error sensitivity matrix of the position of tooth bearing cen-
tre.
7. 4 ERROR S E N S I T I V I T Y M A T R I X O F SECOND-ORDER C O N T A C T
PARAMETERS
The second-order contact parameters include the directions of the contact point paths
( C P P ) on both surfaces, the moving speeds of the contact point (it is assumed that
ds (1) , d5 (2)
the angular velocity of gear 1 is unity) i ,Υ) and τ~7ϊ) » the angular acceleration of
gear 2 relative to gear 1 dy( 12)

, the inclination of the contact ellipse, and the
(dp ) 2
lengths of minor and major axes of the ellipse lx and l2 (see Fig. 7. 3 ) . The influence
of mounting errors on these parameters will be analysed below.
After the movement of the contact centre on tooth surfaces, one of the condition to
d#( d£<
keep surfaces in contact should still be valid on new tooth bearing cen-
d^ a> άφα)
tre. T h u s the equation for the reference point
ω1
άφ{ i) **i + ^ * + *α> x *a) = $>e_i + £p* + W21 <2> χ
* *<2> α 3o)
will become
ft)1 d I co1 , ,
(i1 ||d,| S2 _a_ /_*£_, ,
+ +
(e2 + ψ dJ + 5<» X [*«> + ^ dJ =

\ O si I \ & si j
asM dSi
; :
ß a / ß
!*+§5<*ι + d^πD +
' a 5,; \ a<ff /'+ΪΪΉ
+ (s<2> + S<3> x 5 ( 2 > p ds,| x (#<2> + ^ ds,
\ dSi ) \ d St
Fig. 7. 3 An illustration of some

second-order contact parameters
Compare this equation to Eq. (7. 3 0 ) , we have
a | ω1 w - al x \ Zx d~ex .
a#(1
2
de2 d ft) a e*
+ as hwn k + T7
ä7{ \a(ff d S{ <N * + ;wn
dp a) ^
as,· d* + 5«> x d5,
ß1 W - , 3 ε , , ) . . Ω1 de, ,
l + + dSi
ds, \ W\V ^ ') ' d ^ J7,
+ 3 5,- [dfH l 2 +
3 s,· d^1» a«,·
ds,
3£ < 2 > i L3tf<

α <3) aWiM. \ «> i^l_ . α <2) χ i^_ ^ .
+
χ d s χ Ä + dj +
3 s,· 3S; 9Si
Neglect the terms containing ds?,
ω1 de1 , 3 | S1 \ - , 52 3e 2 , 3 [ S2 \ - ,
A> 3 s,· dii + 1 d5 + d5< +
J7t1 dT^r · d7^ 3^ ai; I d 7 * | ' 2 ds<
d^'^> 3s,·
X ** ds.·
* "3lT d i ' =
W> J7, dSi + 3^ (dH eidSi +
+ έ2ά5
Ä(df^) ·· + Μ2 * ( 2 ) X ^^5,·- ds,' \
α(3) χ α (2)^Σ d 5
3 5;
.| χ Ä <»>
(7.31)
Thus two equations can be obtained by respectively making scalar product with ex and
e2 :
. d ( ω ,· _a_ / J> A«· a

ί ßl
I - A'
\άφ{ö + *
*li ds (7.32)
{
ß2 |
b (7.33)
#21
3 s, \ άφ,(i)|
{ + ^ds. (dî)| +*i*i
where
6 n = cos ψ, b[2 = sin ψ9 b[3 = — 1,
*15_ ld^> as,· +

d^> a s j e i |a
' dSi ' εη + d^> as,· #€l
+ | ξ (α(3) X ä<2>) · (tf<2> X 0 * 2 1 + (ä<2\ ^ , έ,μ« (7. 34)
#2i = — sin ψ9 b22 = cos 0 , b2i = — 1,

ω1 3«! ai2 3 e 2 | α > . £ * 21

^ | + ^ 1}| ϊ . .
#1,25 l>
~
5 = -
U^ 3Si ^ d^ l> a*,-/ 2
Γ ' a*, ' df* 3 s,·
+ 1^
3 5,
(5<3> x S<2>) . (i?<2> x ί,)«« + (5<2\ 3sf
»Φ21 (7. 35)
( 1 > ( 2 )
1 . 1 1 1 edek dek 3£ ,3# , , . j r _ ,n A.
in which the values of -=— , -r— , —-— and —-— can be obtained from Eqs. (7. 4) -
0 Si a Si o Si a Si
(7.14).
de3 de3
The other condition to keep the surfaces in contact during operation , (1) — , , n
should also be valid on the new contact centre. Which means the equation for the
reference point
Ω Ω2
Bl
^ 2 2 ^ro<D ε w 2 (7.36)
~~ ^ Ard»
άφ {
άφα 2 + 2l ^ X e3
will become
<ol_ J_ t_uS_\ .
-l^' + ^ - d ,
d? » ~*~ ds, d « H ^ + ττ,0*}
dkl1' a»2 ί " 1 ^ ^2 ι
- Ui° +- 5 - * - <w. df*» +
3J,· (d?*1*) di * k 2 + — ds,
3 5, \ σ 5,·
(1)
+ 5 x j^ + fjd*
ß1 3 f ß1 \ . '
—k + Tr"*) _dffli +
dsi IdfH ds< (^+ΙΙ^
ß2 3 1 ß2 I , "
- *22> + ~d~s7aSi) d
e2 + ^rds,·
( a Si j
+ 15<2> + ä<3> x S<2> I35,? ds,-| x [ i , + | ^ ds, (7.37)

35,
where
dkf 3 £<2> Π1 02
jfcWJr- 4 . Ml— M (7.38)
dsi
= A
dst as,· 3s, ^ ^'âs,
in which k))l and k)2l denote the partial derivatives of principal curvatures of tooth sur-
faces with respect to the arc length of the lines of curvature at the reference point M.
Compare Eq. (7. 37) to Eq. (7. 36) ,
ω1 J_ (_aS_> ,
ex + -z-^ dsA ds,·
ds, άφα) ^ d 5,· \ dqf» ' ' d Si I
_ *<!>_?_
*<!>_?_ [JL·]
[Ά ΙϊΛ + *ίλ as) as- - *«> — ^ ds-
ki
dSi U?(1>j r 1 ^ dSi aSt as
j · *i dâ> dSi aSt
ω2 d_ I ώ' ■ ,
e2 + -r— dSi dSi
d Si άφα) dSi\ d ^ n I '' d Si )
a>2 5 e2 a*?.
2 fci» dcpa) dsi + <za) X ^ d5,-
a*, U?H l 2 +
a*, Ί ■ dSi d 5/
dkj* Ω1 _d_ ijr_\ ,
dSi
d<pa) +
a Si \d<pa)j ' i έ ι + ä"f d5' I d5'
kl d UH
dsi Γ1 +
a Si d5
'j d5'" *x d^> dsi aSi
Ω2 _a_ IJP_\ i e2 + YJ dsi | ds,·

dSi d^(1) + a Si \d(pa)} '
J2*_ ae,
*i , , Ä(^)(^ + -ds,d "l d " 2
d<pw ds,
a<3> x 5<2> ^ d 5 | x | e + ae
^ 3 d5,-| + a™ X âe3 ds,·
+ 35,
; 3
as,· aj f -
«21
Neglecting the terms containing ds? or ds? leads to
*' d^0 a«, ' ' as,· U ? H eiC15

· as, d^l) eid5
'
*2 d^> as,· dSi kz

ds, | d ? H 2
'
2
3 £2° ω - , , -,,, de, ,
e2 dSt + α χ d5i
--Ts-dw rf
~ ' d9?a) 3 J , i(
*» 3 s,· UfH x
3 s,· d^'> £l d i i
L(» ^ 2 3
** A L(I> 3 I ÖM - J a
^" ^2 - J
π πl) —
1 1
Α ^ d^ as ; ds,· - Λ ^ »as,
^ (Uj^r > | ε2 ds,· - ^ - -d^^
-ds, e2 ds,·
(ä<3> X α <2) ) X έ 33Σ

^ ds,· + α<2> X | ^ ds,·
+ '3 s, ds,
Thus other two linear equations can be obtained by making scalar product with ex and
e 2 , respectively. After simplification,
(7 39)
^ 1 d^>) + b ^ 1 w ) + bi3
^ 1 w\= bu
·
where
#31 = - k[l> cos ψ, bU = - *<» sin 0 , 6'33 = k[2),
,, a£< n S1 , , , ( 1 ) ωι de, - . dkP Z2 . , . _ α ) ω2 de2 -
_ dkT J?_ _ Jl_ dt*,- |-(21) Bin i\+ §Σ (5 «> -(2> - , w

ds{ d^> *2 d9(1) as, 1+
\ 9ds< ' Ί + ds}a *a ' e2) *21
(7.41)
b\x = *{l> sin 0 , b\2 = - *Jl> cos 0 , 6'44 = /fe<2\
* " = - T * 7 d ^ Sln * + *{φ> 77, ·*2 + ΎΊ7 W cos 0 + * ? d F rf * e2

_ dkl_ h^ _ jv_ ai, / a^s \ _ aE
(1 Λ1 e 2
^ Γ ' a S i ,ε,C22 | a*,1u ,α ,ex>) w21
Ä1
a5,· d? > d^> a ^
,wi> Pc. 2"h ω ,
(7.42)
Using Eqs. (7. 3 2 ) , (7. 3 3 ) , (7. 39) and (7. 40) together, the values of JJ ί - ρ ϋ ,
2 1 2
a / ω \ d l Ω \ a / Ω \
Hi [ d ^ > | ' älj [ d^> J a n d ä ^ \ d^> Can b e d e t e r m i n e d
· Similar to the linear Eqs.
(7. 1 8 ) , (7. 2 0 ) , (7. 21) and (7. 2 6 ) , the coefficients are independent of index i .
With the values of these four parameters, the responce of the second-order contact
parameters to the ith mounting error can therefore be analysed.
The moving speeds of the contact point on Σ α ) and Σ ( 2 ) can be expressed by

d*(1) _ /( S1 y d5 ( 2 ) Ωι γ Ω2 \
άφα) V\d^ a ) | + n
d^ j d?(1) α
άφ η άφαη
(7.43)
Their rates of change with respect to s, will be
d_ ( d5(1) ω1 d I ω1 ω2 d I ω2 d5(
(7.44)
ds{ \dp ( 1 ) ά<? ds, \ d p ( 1 ) /
Ώ
' dp (1)
3 s, \ d ^ n dp ( 1 )
a ids 0 Ωι d_ I Ω1 Ω2 d I Ω2 ds ( 2 )
ds< \άφα) d ^ n ds{ \άφα) + d^ (1)
as,· U ^ n dp ( 1 )
(7.45)
The directed angles from the first principal direction to the direction of CPP on the
surfaces (see Fig. 7. 3) can be expressed a s :
Ω2 / Ω1
0 = tan" 1 1) 1) 0<2) = tan" 1 (7.46)
d^ /d^
Figure 7. 4 illustrates the situations of the moving frame and CPP on Σ ( 2 > before and
after a relative movement between the axes in ith direction.
Fig. 7.4
From Fig. 7. 4 it is known that the rotation of the frame have to be taken into ac-
count in the calculation of the rates of change of the directions of CPP on the sur-
faces. They are absolute derivatives of 0 a > and 0<2> :
a)1 d I at· co2 d I ω]
17/» = ψ- + £- =
d S Sd
+ j ^
d S{
(7.47)
i i I ^(1) \ 2
d^)
fl1 d l Ω2 fl2 d ( Ω1
d?> a 5,· \ d^(1> /
(1) n
d ^ a Sf \ d ^ °
>_ d_6^_ fl[ = fl?
Uf 3 5, 5 5, (2) 2 + j ^ (7.48)
d5 |
Under the designed mounting distances, when the contact is at the reference point,
the angular acceleration of the gear relative to the pinion is:
dy 2>
ΰ <»I+*<21)-Ä
(dj/»>)« (7.49)
(a(2\n ,i?<2>)
Its rate of change with respect to sf can be obtained as follows:
3Σ
3 5,
+ (-<21>^l?)+^<3)x^)(^Xd^)-
3Ä < ! ) de (1) 3*<'> de3
+ e«>, d«*° I "21
ί,- d? lα ' as,· d^>
+ v(zu ' 3i.-ld^ lf>> / ^+ ( d ^ ) 2 |^(a< 3 > X 5<2>) · (Ä«> X n)

<7 5,·
9Rm
3 I dY 2 >
+ [*>-*£■ ·=)+(*-· *-·!?
3s,[ (d?* 0 ) 2
( * ( 2 \ n ,£ ( 2 > )
(7.50)
where
a {3RW ei+ 3 I ai2 \ - _ω|_ dji

as,\ d^x) Mw^ 3 i , U ? H e'+ d<ffl> ds,
Λ (7.51)
df*» ds,â 3 5,·
d
3 ί 3e 3 J±l JL + k-LljiL\\ i - k^—iii
dsAdf^l 3 5, d^°
3i, dfM> ^ ' 35,U^l>jJ ' *l dfC» 3 5,
2
«i>J_i_i!i_| ω 3e 3e 3
+
^ * 3s,U^l)l *ίη33Π
d9?a> ¥Τ
3 5, + -
(1>
X a¥f.
5,
(7.52)
The rate of change of the directed angle ψ , which is from ex to ex , can be obtained
from
cos ψ = βι · ελ
Therefore,
sin ^ T 1 = — · ex + el · —
3 5, 5 5, d Si
= . , , a^ n α-a)
Sf sin - sin ψ — — sin 0
a^ * + Τ^Γ 'w d 5,·
5 2> 3
^ "(2) - ' , Σ -(3) " · ,
—^-— aKi) · n sin 0 — -— aK6) · n sinr 0
a 5, ^ d Si
which can be simplified to:
τ ^ = T 1 + -^— α(2> · n + ^ α<3) · n - ^ ^ - α (1) · η (7. 53)

a 5, a 5, a 5, a 5,· a 5, a 5,
The directed angle from ex to the first principal direction of the difference surface tx
(see Fig. 7 . 3 ) i s :
1 . — # <2> sin20
A<1> = — tan
tan
L
(7.54)
£<1> - R^COS :—2ψ
—
where
fl = tta> _ Ä ) / 2 f Ä «> = ( Λ «) _ Ä <i))/2 (7.55)

The derivative of λ£η with respect to 5,· can be determined by:
4 | ^ [(£< 2 ) ) 2 - Rw Ri2> cos 2φ\ - sin 2ψ

a S{
I Γ*α>ί Ϊ*Ρ - * * £ ) - R™[ * * £ - * * £ | 1 I

IL^ \ dSi ds{ I \ dSi dSi ) \ \
3 Sj
(7.56)
4[(# ) + (#(2)) -
(1) 2 a)i2)
2R R cos 2 0 ]
From Fig. 7. 3 it is known that the directed angle from ει to *iis
A«) = A<» - 0 (7.57)
Thus its rate of change is
3Λ<2) = 2λ£> _ djf>

d Si d Si d Si
(7.58)
Fig. 7.5
Therefore, the rates of rotation of instantaneous contact ellipse relative to the tooth
surfaces will be (see Fig. 7. 5) :
Γ?» = ψ^ + Ρ- 77» = ψ^ + ^- (7.59)
From Euler's theorem it is known that the principal normal curvatures of the differ-
ence surface at the reference point are
*«i> = £<2>cos2 λ™ + /&<2)sin2 A<2) - jfe^cos2 A«> - y&^sin2 A<n (7. 60)
£<2i> = £<2>sm2 A<2) + £<2)cos2 A<2) - /fc^sin2 A<n - yfe^cos2 A<x) (7. 61)
Their rates of change can be expressed as follows:
p 1(21) oi(2) pl(2) a L<1) 3A<1>

* | i _ = fiL. c o s 2 A «> + φ - sin2A<2> - ψ - co8*4» - ^ - sin2A«>
σ 5,· σ 5,· d 5,· σ 5,· σ 5,·
(1) (2) 2)
+ 2# ^ P - sin 2A<*> - 2JR V ^ sin2A< (7. 62)
g 8
d S{ d Si
Ol(21) p L(2) p L<2) ol(l) o 1(1)

^ ? - = ^ - sin 2 A«> + ^ 2
- cos 2 A<2> - ^ sin 2 A<» - ^ - cos 2 A<»
σ 5,· σ 5,· σ 5,· a 5,· co,·
3 A <2) 3 A (1>
<2) sin 2) (1)
+ 2# V- 24 - 2# ^ - sin 2A<!> (7. 63)
d Si d Si
When the gear pair is under running test with marking compound on the tooth sur-
faces, the area where the distance between the surfaces is less than the thickness of
the marking compound δ can be regarded as the contact spot when the load is fairly
light. The instantaneous contact spot can be taken as an ellipse and the length of mi-
nor and major axes of which can be found as follows:
ll = ll = (7,64)
vW ' iw"
Their rates of change are :
a/1= 1 h dkj21> djz =

(7.65)
dsi~ 2 k{ n)
dsi ' dsi~ 2 ^21) dsi
After the index i changes step by step from 1 to 4» a 4 X 9 matrix as follows is ob-
tained:
' 3 1 dia>\
a)
3 |ds < 2 M
C7ix> c/p> a dV2 d_li dl2
3Sl Up l 3 5, U f H 3 5j Ud^)2 d Si d Sx
3 /di°M a dy2 (2) dji

a*2 \d?H ϋί°
[/£2> T(2)
3s2 \άφ«η 3 i 2 (d^°) 2 ds2 d s2
Φ = a
3 [di M d Ids'"] 3 d2y<2> dlx
a s3 U ? H 3s3 U ? H £7i» £/?> 3 s3 [(d^>) 2 d s3 d 53
3 /dj"M a ids'"]
t/i1' c/l2) a ' dV 2)
j-d) 2^(2)
3st U ? H 3 st \ d ? H 3 s 4 l(d> ( 1 > ) 2 d St d 54J
(7.66)
From the production of the mounting error Δ and the above matrix, the rates of
change of the second-order contact parameters can be found. This matrix can map
the mounting errors into the second-order contact parameter space, is called the er-
ror sensitivity matrix of second-order contact parameters.
7. 5 T H E BACKGROUND O F APPLICATION
Error sensitivity matrices may be applied to many practical situations, e. g. in quali-

ty control for reasonable designation of the tolerance in manufacturing and assembly,
and for improvement of the structure of transmission device. They can also be used
in gear lapping process for accurate determination of the relative movement between
the axes. This mathematical model itself is an important method for a further inves-
tigation of contact characteristics of gear pairs. However, at this s t a g e , only brief
description of some possible applications can be presented here.
The most direct application is to determine the rates of change of contact situations
according to known mounting errors. However, the authors believe this application
to be limited to some special situations. We shall discuss below how the error sensi-
tivity matrices can be used for determination of tolerance.
In above mentioned matrices, there are totally thirteen contact parameters involved.
However, in practice it is unusual that every one of them is important and one is only
interested in several of them. For practical purposes, the columns of unimportant
parameters can be deleted, and the important columns can be combined in a new ma-
t r i x , denoted by ΦΜ» For spiral bevel and hypoid gears, the important parameters
a r e : the position of the centre point of tooth bearing on the gear flank, the direction
of CPP on gear flank, the angular acceleration of the gear relative to the pinion, and
the length of contact ellipse when the contact is at the centre point of tooth bearing.
In this case the error sensitivity matrices can be simplified to
1 dy 2 ) \
d Sx d Sx
U{» ds d SY
2)
I dy \
o S2 d S2 ds2 \I (df*
(d^yl ds2
ΦΜ = (7.67)
d_ 1 d y ( 2 ) \ dh
O S3 a S3
UP a) 2
ds3 I (d? ) ) ds3
£L £L £/<«> j _ 1 dY 2 ) \ dl2
4
[d 5 4 d 54 d S^
The absolute values of the elements in this matrix form a new matrix, denoted by
ΦΜΑ- Then we define a 1 X 4 matrix P , where the elements are denoted by/>,. Set px
= 1, the other elements being the relative accuracy of s2, s3 and 54 with respect to sx,
which can be achieved for a certain manufacturing condition. Let the product of P
and ΦΜΑ b e Q ,
qi = Σ &MAi,jpj
Let qA19 qA2f QAS* QAA and qA5 denote the permitted deviations of ß 1 , ^ 2 , C7<2>, _dy^_2
(d^>)
and l2, the minimum of the ratio —'- is denoted by kmin, which is the amplifying coef f i-
qAi
cient of />,·. The productions 2p,kmin can be taken as the tolerance limit of sf·. Obvious-
ly, the tolerance field determined in this way is a hyperrectangular in 5,-space.
The method mentioned above is simple, but not economical, because it does not
make use of the correlation between the mounting errors. We discuss below a
method which can offer a larger mounting error field. Let W denote a set of permit-
ted contact parameters in the contact parameter space. It is assumed to be a simply-
connected convex field. Since ΦΜ is a 4 X 5 matrix, no inverse matrix can be found.
So it needs to be divided into two. We delete separately the ith and 7th columns from
ΦΜ to get two square matrices ΦΜω and ΦΜΟ> In the contact parameter space, the ith
and 7th contact parameters should be independent to the others. For example, if the
permitted field of tooth bearing centre is an ellipse, Ω1 and ß 2 are dependent on each
other, the first and the second columns cannot be deleted. The corresponding sub-
sets of W in the subspaces are denoted by W(i) and W 0 ) . Mapping them separately in-
to 5,-space using ΦΜ<Ο and ΦΜ\» , two images VA<0 and VAij) can be obtained. The in-
tersection of t h e m V ^ = VAi0 f] V r A 0 ) is a set of permitted mounting errors. The lat-
ter obtained in this way is generally not a hyperrectangular. Therefore the condition
as to whether a transmission set is qualified, has to be determined from comprehen-
sive inspection result.
For some structure there are usually one or two mounting distances which can be ad-
justed in assembling process. For example, if Si'is adjustable, the projection of V A on
the hyperplane formed by s 2 ,s 3 ands 4 can be taken as tolerance field of these three pa-
rameters. In the assembling process, sx can be adjusted to bring the relative position
between gears in VA. The tolerance field is thus enlarged without the contact quality
being reduced.
When the transmission device is under load, it is unavoidable that the relative posi-
tion between gears will change. However, it is desirable that the position of the
tooth bearing centre on gear flank and the relative angular acceleration between
gears change as less as possible. This condition can be expressed as follows :
ß l Q l Ω1 Ω1
A i A , A . A
— v S \ , a / dy 2 > \ J
3sx \ ( d p a ) ) 2 / a51
^ ds2\ ( d ^ a > ) 2 / a$z
, a / d2y>(2) \ , , d i dV2> \ . I
As long as this system of homogeneous equations is linearly independent, it has non-

trivial solution (dsi, ds 2 , ds 3 , ds 4 ) . If the relative movement between the gears is in
line with this solution, the three contact parameters will nearly remain unchanged.
Although this condition is not easy to be fully implemented, we can change the
structure of the transmission device to make the direction of deformation close to this
solution. This means that the nontrivial solution provides the designer with both cri-
teria and improvement possibility of the structure of a transmission device.
7. 6 T H E R E L A T I O N S H I P B E T W E E N ERROR S E N S I T I V I T Y M A T R I C E S
AND V E R T I C A L ( V ) AND H O R I Z O N T A L ( H ) CHECK R E S U L T S
In practice it is usual to apply the results from V and H ckeck as the criteria of
steadiness and error sensitivity of contact performance of spiral bevel and hypoid
gears (see Chapter 3 ) . However, V and H check is only a special case of misalign-
ments. In comparison with error sensitivity matrices, V and H check can only pro-
vide limited information. We discuss below the relationship between them and the
procedure to obtain V and H check information from the matrices.
During V and H check process, the angle between gear axes Σ is kept unchanged,
so ds 4 = 0. In order that the backlash of the gear pair do not change rapidly, there is
a special ratio b e t w e e n d s i a n d d s 2 , i. e. in the horizontal plane, the angle between the
direction of relative movement and α α > is equal to the pitch angle of the pinion / .
Therefore,
d
" = ~ sin (SE + r) d51 (7>69)
Let 7 denote the angle between e t and the longitudinal direction of gear tooth surface,
s* the moving distance of the centre point of tooth bearing along the longitudinal
line, we have
Ω1 = cos η as* , Ω2 = sin η as*
Therefore,
ΓΩ1 sin Ύ Ω1 Ί , , Ω1 , , #
: d5
Ö —^v« i ΎΛ T~ i + ö~" d s 3 = cos η as
Id S1 Sin (Σ + ' ) ds2J d 53
(7.70)
2 2
ΓΩ sin y Ω Ί , , Ω2 , . , #
: d5
^ — ^ i v^ Έ~ i + ^~ d5 3 = sin η as
Id Si Sin (2J + / ) d Szl d 53
from which -τ-τ and 1—7 can be determined. These values are the amounts of move-
as as
ment in V and H directions for the centre point of tooth bearing moving 1 mm along
as
the longitudinal direction. From the ratio between dsi and ds2 , 1—7 can be deter-
mined. From the products of -r-7 9 T T 9 T~f 9 0 and ΦΜ» the rates of change of
the second-order contact parameters under V and H check can be found.
7. 7 NUMERICAL EXAMPLES
A pair of hypoid gears in mesh is taken for numerical examples to illustrate the
mathematical model presented in this chapter. The basic parameters of the gear pair
have been presented in Chapter 1. The parameters at the reference point on the con-
cave side (drive side) of the pinion are as follows:
Ray = 5 . 80467 ϊ + 151. 43496 ~j - 31.19278 k

*Ί = - 0. 47247 i - 0.17247 ~j - 0. 86431 k
~ez = 0 . 67400 1 + 0. 56117 J - 0. 48042 k
n = 0 . 56789 1 - 0. 80953 J - 0.14889 k
ki» = - 0 . 027664, W = 0. 0055076
k{\\ = 1 . 9050* - 3 k[\\ = 1. 2727* - 3
W\ = - 3. 7014* - 5 ki]l = - 2. 3595* - 5
The parameters at the reference point on the convex side (drive side) of the gear are:
R{2> =40. 80467 ϊ + 124. 80318 ~j - 31. 63147 I

ii = 0 . 82310 1 + 0. 55817 7 + 0 . 1 0 4 6 3 k
e2 = - 0.15966 1 - 0.18197 7 + 0 . 98330 k
l$2) = 0 . 0068205 ki2) = 0. 0038193
*ίϊί = - 7. 0062* - 6 k[*\ = - 7. 5521* - 6
k?\ = 1 . 2562* - 5 k¥\ = 1. 6527* - 4
The second-order contact parameters are listed below:
υ = 0°, / 2 = 17. 657 mm, * = 17. 925°, (dJ1))2 = - 0.0004

W
ds(1) ds(2)
j-jü) = 22.1750 mm/rad, -7-^ = 10. 5240 mm/rad,
By means of the algorithms presented in this chapter, the error sensitivity matrices
are found as follows :
- 4. 5154« + 1 1. 1164« + 1 8. 3065« + 0 2. 0942« + 1

2. 0852« + 1 3. 8909« + 0 4. 0188« + 0 — 1. 4046« + 1
Φι =
5. 7898«+ 1 1.1833« + 1 1.1226« + 1 - 4. 2237« + 1
2. 6195« + 3 1. 6674« + 2 1. 6141« + 2 - 1. 8201« + 3.
-46.86 -2.460 1.358 0.3586

29.31 1.879 - 0. 585 - 0. 2909
Φ2 =
80, 95 7. 135 -1.317 -0.2024
3221 511.9 -32.08 54.75
3.291« - 4 1.901 0.2517 - 1.777 - 0. 334

- 1.712« - 4 - 0. 892 - 0.1477 1.109 - 1. 000
- 1.134« - 4 - 2. 485 - 0. 4053 3.121 0.012
2. 984« - 2 - 112.1 - 18.59 129.6 316.7
Figure 7. 6 illustrates the influences of s, on the position of the centre point of the
contact pattern on the gear tooth surface. The amount of si9 s2 and s3 are individually
1 mm. Since lrad is too large for s 4 , here 1° is used instead.
Now we use the first method presented in above section to determine the tolerence
limit of 5,·. From Φγ and Φ2 it is known that the absolute values of <PMi.j are
8. 3065 20. 942 0. 3586 3. 291« -- 4 0.334

4.0188 14.046 0. 2909 1. 712« -- 4 1.000
Φ. =
11.226 42.237 0. 2024 1. 134« -- 4 0.012
2.8171 31.767 0.9556 5.208« - 4 5.527.
Suppose the relative accuracy matrix P is [ l , 1, 0. 2 5 , 0. 2 ] , the product of P and

ΦΜΑ will be [15. 695, 15. 9 0 1 , 0. 8 9 1 , 6. 328e — 4 , 2. 442], Let the permited devia-
~ ~ dV 2 )
tions of Ω\Ω\ U{ 9 and / 2 be ( 2 , 1. 5 , 0. 1, le — 4 , 1. 2 ) , we have km
(d^°)2
0.0289. Therefore, the tolerance limit of s, will be ( ± 0 . 0289, + 0 . 0289,
±0.00723, ±20.8").
Fig. 7. 6 The influence of s, on the

position of tooth bearing centre
Now we determine the nontrivial solution of 5,-for keeping the contact situation nearly
unchanged. Substituting the values from Φχ and Φ2 into Eq. (7. 68) > we have
8. 3065 d*! + 4. 0188 ds2 + 11. 226 ds, + 161. 41 ds4 = 0

20. 942 di! - 14. 046 ds2 - 42. 237 ds3 - 1820. 1 ds4 = 0
3. 291 ds! - 1. 712 ds2 - 1. 134 ds 3 + 298. 4 ds4 = 0
Thus the nontrivial solution of ds, for the position of gear tooth bearing centre and
the angular acceleration of the gear relative to the pinion being kept nearly un-
changed can be found as
dsl :ds 2 : ds 3 : dsA = 1 : 17. 205 : - 7. 7372 : 0. 058278
Then we find out the rates of change of the contact parameters under V and H
check. From Eq. (7. 70) we have
d5i as? ds, dsA

T 4 = 0.061606, -Hr = — 0.010573 χ 4 = 0. 042053 τ4 = 0
as as as as
From the product with Φ 2 , the rates of change of the second-order contact parame-
ters can be obtained as follows:
EAl> = 0. 03447
as* U, 1)f
H ="0 . 2 0 7 8 τ-τ^τ-τπΙ =0.1287,
ds* \άφ<
UVP = 0. 01666 -^ ( f^tuy) = 1· ?32e - 5 T ^ = 0. 02204
Γ
ΓΡ = 0. 0000228 τ 4 = 0. 01006 J T = - 0 . 009499
The geodetic curvature of the longitudinal line of the gear tooth surface is GL =
0. 0014160, so the changing rates of the angle between the profile direction and the
contact point path on the gear flank and the angle between the major axis of the in-
stantaneous contact ellipse and the longitudinal lind are determined as follows:
= i/«)
l!L = U{P _- GL
GL == 0.
0. 01524
01524 rraadd//m
mmm,, —^ = GL — Ti2) = 0. 001393 r a d / m m
These parameters compare very well with the results from the analysis of the rates of
change of contact situations under V and H ckeck, and the results from TCA pro-
gram which have been presented in Chapter 3.
7.8 CONCLUSION
In this chapter a mathematical model is presented to describe the responses of the

contact situations of a combined mismatched gear pairs to the misalignments. Some
latent applications are also discussed. The authors believe that these applications
may be interesting and beneficial to the designer. Further investigation into other ap-
plications are possible since this chapter pioneers a new research area.
References
1. K r a n z e r , T . J. "Computer Aided Corrective Machine Setting for Manufacturing

Bevel and Hypoid Gear S e t s " , AGMA Fall Technical Meeting, Paper No.
84FTM 4 , Washinton, D C , October 1 5 - 1 7 , 1984.
2. Kranzer, T. J. "Tooth Contact Analysis of Spiral Bevel and Hypoid Gears Under
Load" , SAE Preprints n 810688 for Meeting April 6 — 8, 1981.
3. Litvin, F. L. and G u t m a n , Y. "A Method of Local Synthesis of Gears Grounded
on the Connections Between the Principal and Geodetic Curvatures of Surfaces" ,
ASME Journal of Mechanical Design, Vol. 103, January 1981, pp 114 — 125.
4. Litvin, F. L. T s u n g , W. J. Coy, J. J. and Heine, C. "Method for Generation of
Spiral Bevel Gear With Conjugate Gear Tooth Surfaces", A S M E , Journal of
Mechanisms, Transmission, and Automation in Design, Vol. 109, June 1987, pp
163-170.
5. Litvin, F. L. T s u n g , W. J. Coy, and L e e , H. T. " Generation of Spiral Bevel
Gear With Conjugate Tooth Surfaces and Tooth Contact Analysis" , NASA Con-
tract Report 4088, August 1987.
6. Baxter, M. L. "Second-Order Surface Generation" , Industrial Mathematics, Vol.
2 3 , part 2 , 1973.
7. Baxter, M. L. "Exact Determination of Tooth Surfaces for Spiral Bevel and Hy-
poid G e a r s " , A G M E - paper, No. 139, Oct. 1966.
8. W a n g , X. C. "Third Order Contact Analysis and Optimal Synthesis of Tooth Sur-
faces" , Proceedings of the Seventh World Congress on Theory of Machines and
Mechanisms, Sevilla, Spain, 1987, pp 1359 — 1362.
9. W a n g , X. C. Ghosh, S. K. and Link, D. "Analysis of Combined Mismatched
Tooth Surfaces up to and including Third Order Contact" , European Journal of
Mechanical Engineering, Vol. 37, N ° 4 , 1992.
REFERENCES 183
10. W a n g , X. C. G h o s h , S. K. and W u , X. T . " A Direct Method for Calculating

Parameters of Tooth Surfaces up to and including Third Order" , European Jour-
nal of Mechanical Engineering, Vol. 3 8 , N° 1, 1993.
11. W a n g , X. C. G h o s h , S. K. and W u , X. T. "Analysis of the Rates of Change of
Contact Situations of a Gear Pair under Vertical ( V ) and Horizontal (H)
Check", European Journal of Mechanical Engineering, Vol. 3 8 , N° 2 , 1993.
12. W a n g , X. C. G h o s h , S. K. and W u , X. T . " A Direct Method for Determining
the Parameters of Mating Tooth Surfaces according to Predetermined Contact
Situations" , European Journal of Mechanical Engineering, Vol. 3 8 , N° 3 , 1993.
13. W a n g , X. C. G h o s h , S. K. and W u , X. T . "A Simple Method of Obtaining Ma-
chine-Setting Parameters for Spiral Bevel and Hypoid Gears" , European Journal
of Mechanical Engineering, Vol. 3 8 , N° 4 , 1993.
14. W a n g , X. C. G h o s h , S. K. and W u , X. T . "An Optimal Synthesis of Spiral Be-
vel and Hypoid Gears" , European Journal of Mechanical Engineering, Vol. 39,
N ° l , 1994.
15. W a n g , X. C. G h o s h , S. K. and W u , X. T . "Analysis of the Sensitivity of the
Contact Situations with respect to Mounting E r r o r s " , European Journal of Me-
chanical Engineering, Vol. 3 9 , N ° 2 , 1994.
16. W a n g , X. C. L i , Y. B. G h o s h , S. K. and W u , X. T . "Curvature Catering — A
New Approach in Manufacture of Sculptured Surfaces ( P a r t 1. t h e o r e m ) " ,
Journal of Material Processing Technology, 38(1993).
17. W a n g , X. C. L i , Y. B. G h o s h , S. K. and W u , X. T . "Curvature Catering — A
New Approach in Manufacture of Sculptured Surfaces (Part 2. methodology)" ,
Journal of Material Processing Technology, 38(1993).
Apppendices
Computer programs for calculating machine setting parameters and analyzing and op-
timizing the contact performance of a pair of hypoid gears are listed below. In order
that the programs are easy to read, subroutines are listed separately. The programs
are written in Pascal. The programs for the design of gear blank and calculating the
machine setting parameters of the member gear are not involved in the appendices.
Before describing the subroutines, some definitions of the types of variants are listed
below :
type
vector3=array[1■ ,3] of double;
vector4=array[1, ►4] of double;
matrixl=array[1. ,2,1..3] of double;
matrix2=array[1, ,3,1.. 3] of double;
matrix3=array[1, . 4,1. .5] of double;
matrix4=array[1, ,4,1. .4] of double;
matrix5=array[1..4,1 9] of double;
1 SUBROUTINES
The common functions and procedures are listed as follows ·
1.1 Scalar Product of Two Vectors:
function np(a,b:vector3):double;
begin
np:=a[l]*b[l]+a[2]*b[2]+a[3]*b[3]
end;
1. 2 Magnetude of a Vector:
APPENDICES 185
function mv(c:vector3):double;
begin
mv:=sqrt(np(c,c) )
end;
1. 3 Vector Product of Two Vectors:
procedure vp(var d:vector3; e,f:vector3);

begin
d[l]:=e[2]*f[3]-e[3]*f[2];
d[2]:=e[3]*f[l]-e[l]*f[3];
d[3]:=e[l]*f[2]-e[2]*f[l]
end;
1. 4 Triple Product of Three Vectors:
function mp(g,h,i:vector3):double;
var j:vector3;
begin
vp(j,h,i); mp:=np(j,g)
end;
1. 5 The Sum of the Products of Two Vectors and Their Coefficients:
procedure vsfvar k:vector3; l,m:vector3; a,b:double);

var i:integer;
begin
for i:=l to 3 do k[i]:=a*l[i]+b*m[i]
end;
1. 6 A Vector Rotates an Angle about a Unit Vector:
procedure vrfvar r:vector3; n,o:vector3; ctdouble);

var
i:integer;
p,q:vector3;
pi,p2,p3,p4:double;
begin
pi:=np(n,o);
p2:=cos(c);
p3:=-pl*p2;
p4:=sin(c);
vp(q,o,n);
vs(p,o,q,p3,p4);
vs(q,o,n,pl,p2);
for i:=l to 3 do r[i]:=p[i]+q[i]
end;
1. 7 A Tensor Formd by Two Dyads:
procedure dv(var s:matrix2; t , u , v , w : v e c t o r 3 ; a,b:double);

var i , j : i n t e g e r ;
begin
f o r i : = 1 t o 3 do
f o r j : = l t o 3 do s [ i , j ] : = - a * t [ i ] * u [ j ] - b * v [ i ] * w [ j ]
end;
1. 8 The Product of a Vector and a Tensor:
procedure vtp(var x:vector3; y:vector3; z:matrix2);

var i,j:integer;
begin
for i:=l to 3 do begin
x[i]:=0;
f o r j : = l t o 3 do x [ i ] : = x [ i ] + y [ j ] * z [ j , i ]
end
end;
1. 9 The Root of a Set of Linear Equations with Two Unknowns:
procedure eq(a:matrixl; var cl,c2:double);

var c3:double;
begin
c3:=a[l,l]*a[2,2]-a[l,2]*a[2,l];
cl:=(a[l,3]*a[2,2]-a[2,3]*a[l,2])/c3;
c2:=(a[l,l]*a[2,3]-a[2,l]*a[l,3])/c3
end;
1.10 The Root of a Set of Linear Equations with Four Unknowns:
procedure eq4(a:matrix3; var bl,b2,b3,b4:double);

var
i,j,k,n:integer;
x:vector4;
p , t:double;
begin
for k:=l to 4 do
begin
p:=0;
for i:=k to 4 do
if abs(a[i,k])>abs(p) then
begin
p:=a[i,k]; n:=i
end;
if n>k then for j:=k to 5 do
begin
APPENDICES 187
t:=a[k,j];
a[k,j]:=a[n,j];
a[n,j]:=t
end;
for j:=k+l to 5 do a[k,j]:*a[k,j]/p;
for i:=k+l to 4 do
for j:=k+l to 5 do
a[i,j]:=a[i,j]-a[i,k]*a[k,j]
end;
k:=4;
repeat
t:=a[k,5];
for j:=k+l to 4 do t:=t-a[k,j]*x[j];
x[k]:=t;
k:=k-l
until k=0;
bl:=x[l]; b2:=x[2]; b3:=x[3]; b4:=x[4]
end;
2 MAIN PROGRAM FOR MACHINES WITH CUTTER-TILT MECHANISM
program c t ( i n p u t » o u t p u t ) ;
label 101,102,103,104,105,106,107,108,109,110,111;
const
cl=1.66666666667; hd=0.01745329252;
type
vectorl=array[1·.49] of double;
vector2=array[1..18] of double;
matrixl=array[1..2,1..3] of double;
matrix2=array[1·.3,1.·3] of double;
matrix3=array[1..4,1..5] of double;
matrix4=array[1..4,1.·4] of double;
matrix5=array[1..4,1..9] of real;
matrix6=array[1·.8,1..41] of double;
var
inf:text;
i,j,k,h,hsl,hs3,hs4:integer;
ezrvectorl; sez:vector2;
al,a2,alf,a2c,ac,af,rl,r2,rlf,r2c,rc,rf,n,nc,nf,cf,ell,
el2,e21,e22,ellf,el2f,e21c,e22c,ef1,ef2,ecl,ec2,vl,v2,
vf,vc,v21,vlf,v2c,o21,olf,o2c,1,If1,lc2,dr,dn,plf,p2c,
q21,qlf,q2c,lgth,por,tl,t2,tfl,tf2,p,q,jj,t,a,b,sl,s2,
s3,s4,vsgm,f,su3:vector3;
sul,su2:vector4;
kll,kl2,k21,k22,kf2,kc2,pll,pl2,p21,p22,prl,pr2,mll,
ml2,m21,m22,mrl,mr2,f21,fr2,c21,cr2,u21,du21,ddu21,ulf,
uf1,u2c,kdsl,kds2,11,12,dsl,ds2,gama,gl,pol,po2,mol,
mo2,lgl,slgl,clgl,slg2,clg2,spc,cpc,smc,cmc,kapa,skp,
ckp,bt,sbt,cbt,batc,s2c,hl,h2,sgm,cgm,ddsl,dds2,ogl,
og2,ql,q2,dll,dl2,dvv,dh,nues,du21s,kps,11s,12s,fv,fh,
sp,qf,muv,muh,smuv,cmuv,smuh,cmuh,gamaf,x,af0,ep,ip,jp,
saf,caf,rpf,xbp,cmr,r,vsgmp,gl,g2,g3,g4,g5,g6,g7,g8,g9,
glO,gll,pl,p2,p3,hs2,mul,mu2,ml,m2,m3,m4,m5,m6,m7,m8,
m9,mlO,mml,mm2,mm3,mm4,mm5,mm6:double;
mat:matrixl;
dnc,dn2:matrix2;
out:matrix6;
begin
np:=a[l]*b[l]+a[2]*b[2]+a[3]*b[3]
end;
begin
mv:= sqrt(np(c,c) )
end;
procedure vpfvar d:vector3; e,f:vector3);
begin
d[l]:=e[2]*f[3]-e[3]*f[2];
d[2]:=e[3]*f[l]-e[l]*f[3];
d[3]:=e[l]*f[2]-e[2]*f[l]
end;
var j:vector3;
begin
vp(j,h,i); mp:=np(j,g)
end;
procedure vsfvar k:vector3; l,m:vector3; a,b:double);
var i:integer;
begin
for i:=l to 3 do k[i]:=a*l[i]+b*m[i]
end;
procedure vr(var r:vector3; n,o:vector3; c:double);
var
i:integer;
p,q:vector3;
pi,p2,p3,p4:double;
begin
pl:=np(n,o); p2:=cos(c);
p3:=-pl*p2; p4:=sin(c);
vp(q,o,n);
vs(p,o,q,p3,p4);
vs(q,o,n,pl,p2);
end;
procedure dv(var s:matrix2; t,u,v,w:vector3; a,b:double);
var i,j:integer;
begin
for i:=l to 3 do
APPENDICES 189
for j:=l to 3 do s[i,j]:= -a*t[i]*u[j]-b*v[i]*w[j]
end;
procedure vtpfvar x:vector3; y:vector3; z:matrix2);
var i,j:integer;
begin
x[i]:=0;
for j:=l to 3 do x[i]:=x[i]+y[j]*z[j,i ]
end
end;
procedure eq(a:matrixl; var cl,c2:double);
var c3:double;
begin
c3:=a[l,l]*a[2,2]-a[l,2]*a[2,l];
cl:=(a[l,3]*a[2,2]-a[2,3]*a[l,2])/c3;
c2:=(a[l,l]*a[2,3]-a[2,l]*a[l,3])/c3
end;
var
i,j,k,n:integer;
x:vector4;
p,t:double;
begin
for k:=l to 4 do
begin
p:=0;
for i:=k to 4 do
begin
p:=a[i,k]; n:=i
end;
if n>k then
for j:=k to 5 do
begin
t:=a[k,j]; a[k,j]:=a[n,j]; a[n,j]:=t
end;
for j:=k+l to 5 do a[k,j]:=a[k,j]/p;
for i:=k+l to 4 do
for j:=k+l to 5 do
end;
k:=4;
repeat
t:=a[k,5];
for j:=k+l to 4 do t:=t-a[k,j]*x[j];
x[k]:=t;
k:=k-l
until k=0;
bl:=x[l]; b2:=x[2]; b3:=x[3]; b4:=x[4]
end;
{This procedure is for the calculation of third order
geometric parameters of generated tooth surfaces.}
procedure togp(al,af,n,ef1,ef2,ell,el2,vl,vf,
vlf,olf,plf,tl:vector3;
kf2,kll,kl2,f21,fr2,ulf,dulf,ddulf:double;
var pll,pl2,p21,p22,prl,pr2:double);
var
i,j:integer;
fsl,fs2,fs21,fs32,g,cts,fssl,fss2,fss32,ps21,bts,cbt,
sbt,pss31,pss32,fol,pol,po2,cps,sps,fool,gl,g2,dl,d2
:double; efls,ef2s,ns,vlfs,plfs,nss,qlf,rfo,eflo,ef2o,
no,vlfo,qlfo,noo,si,s2,s3:vector3;
mat:matrix1;
dnfs,ddd:matrix2;
begin
fsl:=np(tl,efl); fs2:=np(tl,ef2);
fs21:=fr2*fs2; fs32:=kf2*fs2;
gl:=-fs21;
vs(ef2s,efl,n,gl,fs32);
for i:=l to 3 do
begin
efls[i]:=fs21*ef2[i];
ns[i]:=-fs32*ef2[i]
end;
vp(vlfs,olf,tl);
dv(ddd,ef2s,ef2,ef2,ef2s,l,1 ) ;
gl:=f21*fsl;
for i:=l to 3 do
for j:=l to 3 do
dnfs[i,j]:=kf2*ddd[i,j]-gl*ef2[i]*ef2[j];
vtp(si,vlf,dnfs);
vp(s2,olf,ns);
gl:=-np(vlfs,ef2)*kf2;
for i:=l to 3 do plfs[i]:=gl*ef2[i]+sl[i]-s2[i];
g:=-np(plfs,tl)/mv(plf); cts:=g-fs21;
fssl:= -fs2*cts; fss2:=fsl*cts;
fss32:=f21*fsl*fs2+kf2*fss2;
gl:=-fss32; g2:=-fs32;
vs(nss,ef2,ef2s,gl,g2);
vp(si,olf,vf ) ; vp(s2,af,vlf);
vs(s3,sl,s2,l,-1); gl:=dulf/ulf;
vs(qlf,s3,vl,l,gl);
fol:=np(n,qlf)/np(olf,ef2);
vs(rfo,efl,vf,fol,l) ;
cps:=np(ef1,ell); sps:=np(ef2,ell);
pol:=fol*cps-np(vlf,ell);
po2:=-fol*sps-np(vlf,el2);
vp(eflo,af,ef1); vp(ef2o,af,ef2);
vp(no,af,n);
vp(sl,olf,rfo); g2:=ddulf/ulf;
vs(vlfo,vl,si,gl,1);
vs(sl,rfo,vf,1,1); vp(s2,al,si);
APPENDICES 191
vs(s3,vl,s2,g2,dulf);
vp(sl,af,rfo); vp(s2,olf,si);
vs(sl,s3,s2,l,1); vp(s2,af,vlfo);
vs(qlfo,sl,s2,1,-1);
fool:=(np(no,qlf)+np(n,qlfo)-fol*(np(ef2o,olf)
+dulf*np(al,ef2)))/np(olf,ef2);
vp(noo,af,no);
dl:=kll*(ulf*mp(al,ell,vlf)-fool*cps+fol*sps*np(olf,n)
+np(vlfo,ell))+ulf*(mp(al,ηο,ell)+kl2*po2*np(al,n))
+dulf*np(al,el2)-np(noo,ell);
d2:=kl2*(ulf*mp(al,el2,vlf)+fool*sps+fol*cps*np(olf,n)
+np(vlfo,el2))+ulf*(mp(al,no,el2)-kll*pol*np(al,n))
-dulf*np(al,ell)-np(noo,el2);
cbt:=np(tl,ell); sbt:=np(tl,el2);
mat[1,3]:=pol*pol*(kll*g*sbt-np(nss,ell))-dl*cbt*cbt;
mat[2,3]:=po2*po2*(kl2*g*cbt+np(nss,el2))+d2*sbt*sbt;
gl:=pol*sbt-po2*cbt;
mat[1,1]:=2*pol*cbt*gl;
mat[1,2]:=sqr(pol*sbt)-sqr(po2*cbt);
mat[2,1]:=mat[l,2];
mat[2,2]:=2*po2*sbt*gl;
for i:=l to 2 do
for j:=l to 3 do mat[i,j]:=mat[i,j]/100;
eq(mat,pl2,p21);
pll:=(dl-2*pl2*pol*po2-p21*po2*po2)/sqr(pol);
p22:=(d2-pl2*pol*pol-2*p21*pol*po2)/sqr(po2);
P rl:=pl2/(kll-kl2);
Pr2:=p21/(kll-kl2)
end;
{This procedure is for the analysis of the third order
contact parameters of mismatched tooth surface.}
procedure tocam(al,a2,rl,r2,ell,el2,e21,e22,n,dr,dn,o21
:vector3; u21,du21,kll,kl2,k21,k22,cpc,spc,cmc,smc,pll,
pl2,p21,p22,prl,pr2,mll,ml2,m21,m22,mrl,mr2,dsl,ds2,
slgl,clgl ,slg2,clg2,ll,12,kdsl, kds2 -.double ;
var ddsl,dds2,gl,g2,ql,q2,dll,dl2,pol,po2,mol,mo2,
ddu21:double);
var
del1,del2,de21,de22,ddn,ddr,si,s2,s3:vector3;
dkll,dkl2,dk21,dk22,po21,mo21,ροοΐ,poo2,mool,moo2,dct,
pa21,ma21,cps,sps,c2ps,s2ps,dps,dlgl,dlg2,dl,d2,d3,d4
:double; mat:matrixl;
begin
pol:=cpc*dsl; po2:=spc*dsl;
mol:=cmc*ds2; mo2:=smc*ds2;
po21:=prl*pol+pr2*po2;
mo21:=mrl*mol+mr2*mo2;
vp(sl,al,ell); dl:=kll*pol;
vs(s2,si,n,1,dl);
vs(dell,el2,s2,po21,l);
vp(si,al,el2);
dl:=kl2*po2; d2:=-po21;
vs(s2,si,n,1,dl);
vs(del2,ell,s2,d2,1 ) ;
pa21:=po21+np(al ,n);
ma21:=mo21+np(a2,n)*u21;
dkll:=pll*pol+pl2*po2; dkl2:=p21*pol+p22*po2;
dk21:=mll*mol+ml2*mo2; dk22:=m21*mol+m22*mo2;
cps:=np(ell,e21); sps:=np(el2,e21);
vs(sl,dr,dn,k21,1); vs(s2,dr,dn,k22,1);
mat[1,3]:=mo2*(k22-k21)*ma21-dk21*mol+mp(o21,si,e21)
+(k21*mp(a2,r2,e21)+np(a2,e22))*du21+cps*((k21-kl2)
*po2*pa21+dkll*pol)+sps*((kll-k21)*pol*pa21+dkl2*po2);
mat[2,3]:=mol*(k22-k21)*ma21-dk22*mo2+mp(o21,s2,e22)
+(k22*mp(a2,r2,e22)-np(a2,e21))*du21+sps*((kl2-k22)
*po2*pa21-dkll*pol)+cps*((kll-k22)*pol*pa21+dkl2*po2);
mat[1,1]:=(k21-kl1)*cps;
mat[l,2]:=(k21-kl2)*sps;
mat[2,l]:=(kll-k22)*sps;
mat[2,2]:=(k22-kl2)*cps;
eq(mat,ροοΐ,ροο2 ) ;
mool:=mo2*ma21-mp(o21,dr,e21)-mp(a2,r2,e21)*du21
+cps*(pool-po2*pa21)+sps*(poo2+pol*pa21);
moo2:=-mol*ma21-mp(o21,dr,e22)-mp(a2,r2,e22)*du21
-sps*(pool-po2*pa21 )+cps*(poo2+pol*pa21 ) ;
ddsl:=cpc*pool+spc*poo2; dds2:=cmc*mool+smc*moo2;
gl:=((pol*poo2-po2*pool)/dsl/dsl+po21)/dsl;
g2:=((mol*moo2-mo2*mool)/ds2/ds2+mo21)/ds2;
dl:=-dkll*pol-kll*pool; d2:=-kll*pol;
vs(sl,ell,dell,dl,d2);
dl:=-dkl2*po2-kl2*poo2; d2:=-kl2*po2;
vs(s2,el2,del2,dl,d2) ;
vs(s3,si,s2 ,1,1 ) ; vp(si,al,dn);
vs(ddn,s3,si,1 ,1) ;
vs(sl,ell,dell»pool,pol); vs(s2,el2,del2,poo2,po2);
vs(s3,si,s2,1,1 ) ; vp(si,al,dr);
vs(ddr,si,s3 ,1,1 ) ;
dl:=2*du21; vs(sl,ddn,dn,u21,dl);
ddu21:=(mp(o21,ddr,n)+2*mp(o21,dr,dn)-mp(al,rl,ddn)
+mp(a2,r2,sl)+2*mp(a2,dr,n)*du21)/mp(a2,n,r2);
c2ps:=cps*cps-sps*sps; s2ps:=2*cps*sps;
dps:=ma21-pa21;
dl:=(kll-kl2)/2; d2:=(k21-k22)/2;
dlgl:M4*dps*d2*(d2-dl*c2ps)-(dl*(dk21-dk22)-d2*(dkll
-dkl2))*s2ps)/(4*(dl*dl+d2*d2-2*dl*d2*c2ps));
dlg£:=dlgl-dps;
ql:=(dlgl+po21)/dsl; q2:=(dlg2+mo21)/ds2;
d3:=dk21*clg2*clg2+dk22*slg2*slg2-dkll*clgl*clgl-dkl2
*slgl*slgl+4*dl*slgl*clgl*dlgl-4*d2*slg2*clg2*dlg2;
d4:=dk21*slg2*slg2+dk22*clg2*clg2-dkll*slgl*slgl-dkl2
*clgl*clgl-4*dl*slgl*clgl*dlgl+4*d2*slg2*clg2*dlg2;
dll:=-0.5*ll*d3/kdsl/ds2; dl2:=-0.5*12*d4/kds2/ds2
APPENDICES 193
end;
{This procedure is for the analysis of the changing rates
of contact situations under V and H check.}
procedure vh(al,a2,rl,r2,ell,el2,e21,e22,n,dr,dn,
lgth,o21,v21:vector3;
u21,du21,kll,kl2,k21,k22,pll,pl2,p21,p22,prl,pr2,
mll,ml2,m21,m22,mrl,mr2,ds2,gl,11,12,dkl,dk2,slgl,
clgl,slg2,clg2,pol,po2,mol,mo2,gama,hd:double;
var dv,dh,nues,du21s,kps,11s,12s:double);
var
i:integer;
ksl,ks2,ks3,ells,el2s,e21s,e22s,ns,ns2,rls,r2s,ls,
drls,dns,sl,s2,s3,s4:vector3;
psl,ps2,msl,ms2,pols,po2s,mols,mo2s,cps,sps,c2ps,s2ps,
pss,ps21,ms21,lgls,lg2s,klls,kl2s,k2Is,k22s,dkls,dk2s,
rols,ro2s,gl,g2,g3,g4,g5,g6,g7:double;
mat:matrix3;
begin
vp(si,a2,al); gl:=mv(sl);
for i:=l to 3 do ksl[i]:=sl[i]/gl;
vp(si,ksl,al);
gl:=sin(gama*hd); g2:=cos(gama*hd);
vs(ks2,sl,al,gl,g2); vp(ks3,ksl,ks2);
msl:=np(lgth,e21); ms2:=np(lgth,e22);
g3:=-k21*msl; g4:=-k22*ms2;
vs(ns2,e21,e22,g3,g4);
mat[1|1]:=np(ell,ks3);
matfl,2]:=np(el2,ks3);
mat[1,3]:=mp(al,rl,ks3);
mat[1,4]:=-mp(a2,r2,ks3);
matfl,5]:=np(lgth,ks3);
mat[2,1]:=-kll;
mat[2,2]:=0;
mat[2,3]:=np(al,el2);
mat[2,4]:=-np(a2,el2);
mat[2,5]:=np(ns2,ell);
mat[3,l]:=0;
matf3,2]:=-kl2;
mat[3,3]:=-np(al,ell);
mat[3,4]:=np(a2,ell);
mat[3,5]:=np(ns2,el 2);
mat[4,1]:=np(al,e12);
vp(sl,al,rl);
mat[4,3]:=mp(al,n,s1);
mat[4,4]:=-mp(a2,n,si);
mat[4,5]:=u21*mp(a2,n,lgth)-np(v21,ns2);
eq4(mat,psl,ps2,rols,ro2s);
vs(s2,ell,el2,psl,ps2); vs(rls,sl,s2,rols,l);
vp(s2,a2,r2); vs(r2s,lgth,s2,1,ro2s);
vs(Is,rls,r2s,1,-1);
dv:=np(ls,ksl); dh:=np(Is,ks2)*g2;
ps21:=prl*psl+pr2*ps2;
ms21:=mrl*msl+mr2*ms2;
gl:=kll*psl; g2:=kl2*ps2;
vs(si,el2,n,ps21,gl); vp(s2,al,ell);
vs(ells,sl,s2,l,rols); g3:=-ps21;
vs(sl,ell,n,g3,g2); vp(s2,al,el2);
vs(el2s,sl,s2,l,rols);
g3:=-kll*psl; g4:=-kl2*ps2;
vs(sl,ell,el2,g3,g4) ; vp(s2,al,n);
vs(ns,si,s2,1,rols);
g3:=k21*msl; g4:=k22*ms2;
vs(sl,e22,n,ms21,g3); vp(s2,a2,e21);
vs(e21s,sl,s2,l,ro2s);
gl:=-ms21;
vs(sl,e21,n,gl,g4); vp(s2,a2,e22);
mat[1,1]:=-np(ell,e21);
matfl,2]:=-np(el2,e21);
matf1,3]:=1;
matfl,4]:=0;
vs(siiells,el2s,pol,po2);
mat[1,5]:=np(sl,e21)+mp(al,rls,e21)-mo2*npie22s,e21)
-u21*mp(a2,r2s,e21);
mat[2,1]:=-mat[l,2];
mat[2,2]:=mat[l,1];
mat[2,3]:=0;
mat[2,4]:=1;
mat[2,5]:=np(sl,e22)+mp(al,rls,e22)-mol*np(e21s,e22)
-u21*mp(a2,r2s,e22);
mat[3,l]:=-kll*mat[l,l];
mat[3,2]:=-kl2*mat[1,2];
mat[3,3]:=-k21;
mat[3,4]:=0;
klls:=pll*psl+pl2*ps2; kl2s:=p21*psl+p22*ps2;
k21s:=mll*msl+ml2*ms2; k22s:=m21*msl+m22*ms2;
mat[3,5]:=k21s*mol+k22*mo2*np(e22s,e21)+mat[1,l]*klls
*pol-kll*pol*np(ells,e21)+mat[1,2]*kl2s*po2
-kl2*po2*np(el2s,e21)-mp(o21,ns,e21);
mat[4,1]:=kl1*mat[1,2];
mat[4,2]:=-kl2*mat[1,1];
mat[4,3]:=0;
mat[4,4]:=-k22;
mat[4,5]:=k22s*mo2+k21*mol*np(e21s,e22)-mat[1,2]*klls
*pol-kll*pol*np(ells,e22)+mat[l,l]*kl2s*po2
eq4(mat,pols,po2s,mols,mo2s);
gl:=(mol*mo2s-mo2*mols)/ds2/ds2;
nues:=gl-gl+ms21;
vs(sl,ell,el2,pols,po2s); vs(s2,ells,el2s,pol,po2);
vs(s3,si,s2,1,1 ) ; vp(s4,al,rls);
vs(drls,s3,s4,1,1 ) ;
APPENDICES 195
gl:=-klls*pol-kll*pols; g2:=-kll*pol;
vs(sl,ell,ells,gl,g2) ;
g3:=-kl2s*po2-kl2*po2s; g4:=-kl2*po2;
vs(s2,el2,el2s,g3,g4) ;
vp(s3,al,ns); vs(s4,si,s2,1,1 ) ;
vs(dns,s3,s4,1,1);
du21s:=(mp(o21,drls,n)+mp(o21,dr,ns)+np(v21,dns)
-mp(al,rls,dn)+u21*mp(a2,r2s,dn)+du21*(mp(a2,r2s,n)
+mp(a2,r2,ns)))/mp(a2,n,r2);
gl:=(kll-kl2)/2; g2:=(k21-k22)/2;
g3:=ps21+np(al,n)*rols; g4:=ms21+np(a2,n)*ro2s;
pss:=g4-g3;
Igls:=(4*pss*g2*(g2-gl*c2ps)-s2ps*(gl*(k21s-k22s)
-g2*(klls-kl2s)))/4/(gl*gl+g2*g2-2*gl*g2*c2ps);
lg2s:=lgls-pss; kps:=gl-lg2s-ms21;
g3:=clgl*clgl; g4:=slgl*slgl;
g5:=clg2*clg2; g6:=slg2*slg2;
g7:=4*(gl*clgl*slgl*lgls-g2*clg2*slg2*lg2s);
dkls:=k21s*g5+k22s*g6-klls*g3-kl2s*g4+g7;
dk2s:=k21s*g6+k22s*g5-klls*g4-kl2s*g3-g7;
lls:=-0.5*ll*dkls/dkl; 12s:=-0.5*12*dk2s/dk2
end;
{This procedure is for the analysis of the error sensiti-
vity of the contact situations with respect to misalign-
ments. However, it is not necessary for optimal synthesis,
procedure errsen(al,a2,rl,r2,frl,l,n,fn,ell,el2,e21,e22,
o21,v21:vector3; u21,pu21,kll,kl2,k21,k22,pll,pl2,p21,
p22,prl,pr2,mil,ml2,m21,m22,mrl,mr2,dsl,ds2,pl,p2,ml,m2,
11,12,lgl,kdsl,kds2:double);
var
i,j:integer;
a3,dell,del2,de21,de22,drl,dr2,dn,dl,a32,r2n,dfrl,dfn,
tl,t2,t3:vector3;
dol,do2,ppl,pp2,pml,pm2,sgm,cgm,psgm,dps,sps,cps,s2ps,
c2ps,lg2,ρρρΐ,ppp2,ppml,ppm2,rp,rm,psp21,psm21,pkll,
pkl2,pk21,pk2 2,gl,g2,g3,g4,g5,g6,g,gg,pg,pgg:double;
mml,mm2:matrix3;
mtl:matrix4; mt2:matrix5;
begin
vp(a3,al,a2); sgm:=mv(a3);
for i:=l to 3 do a3[i]:=a3[i]/sgm;
cgm:=np(al,a2);
cps:=np(ell,e21); sps:=np(el2,e21 ) ;
s2ps:=2*sps*cps; c2ps:=cps*cps-sps*sps;
lg2:=lgl-arctan(sps/cps);
rp:=(kll-kl2)/2; rm:=(k21-k22)/2;
vp(a32,a3,a2); vp(r2n,r2,n);
gl:=-np(a2,r2n);
g2 : =4*( rp*rp+rm*rm-2*rp*rm3»:c2ps ) ;
g3:=sqr(cos(lg2)); g4:=sqr(sin(lg2));
g5:=sqr(cos(lgl)); g6:=sqr(sin(lgl));
mml[1,1]:=0;
mml[l,2]:=0;
mml[1,3]:=mp(al,rl,n);
mml[l,4]:=gl;
mml[2,1]:=(k21-kll)*cps;
mml[2,2]:=(k21-kl2)*sps;
mml[2,3]:=k21*mp(al,rl,e21)+np(al,e22);
mml[2,4]:= -np(a2,e22)-k21*mp(a2,r2,e21);
mml[3,1]:=(kll-k22)*sps;
mml[3,2]:=(k22-kl2)*cps;
mml[3,3]:=k22*mp(al,rl,e22)-np(al,e21);
mml[3,4]:=np(a2,e21)-k22*mp(a2,r2,e22);
mml[4,l]:=kll*np(v21,ell)+np(o21,el2);
mml[4,2]:=kl2*np(v21,el 2)-np(o21,ell);
mml[4,3]:=np(o21,al)*np(n,rl)-np(o21,rl)*np(n al)
+mp(al,v21,n);
mml[4,4]:=0;
mm2[1,1]:=cps;
mm2[1,2]:=sps;
mm2[l, 3] :=-l;
mm2[l,4]:=0;
mm2[2,1]:= -sps;
mm2[2,2]:=cps;
mm2[2,3]:=0;
mm2[2,4]:=-l;
mm2[3,1]:=-kll*cps;
mm2[3,2]:=-kl2*sps;
mm2[3,3]:=k21;
mm2[3,4]:=0;
mm2[4,1]:=kll*sps;
mm2[4,2]:=-kl2*cps;
mm2[4,3]:=0;
mm2[4,4]:=k22;
for j:=1 to 4 do
begin
case j of
1:begin
for i:=l to 3 do dl[i]:=al[i];
psgm:=0
end;
2:begin
for i:=l to 3 do dl[i]:=a2[i];
psgm:=0
end;
3:begin
for i:=l to 3 do dl[i]:=a3[i];
psgm:=0
end;
4:begin
APPENDICES 197
g:=np(1,a2)+np(1,a32)*cgm/sgm;
for i:=l to 3 do dl[i]:=g*a32[i];
psgm:=1
end
end;
mml[1,5]:=psgm*np(a3,r2n)+np(dl,n);
mml[2,5]:=psgm*(np(a3,e22)+k2l*mp(a3,r2,e21))
+k21*np(dl,e21);
mml[3,5]:=psgm*(-np(a3,e21)+k22*mp(a3,r2,e22))
+k22*np(dl,e22);
mml[4,5]:=u21*(psgm*np(a32,r2n)-mp(a2,dl,n));
eq4(mml, ppl,pp2,dol,do2);
pml:= ppl*cps+pp2*sps+dol*mp(al,rl,e21)-do2
*mp(a2,r2,e21)-psgm*mp(a3,r2,e21)-np(dl,e21);
pm2:=-ppl*sps+pp2*cps+dol*mp(al,rl,e22)-do2
psp21:=prl*ppl+pr2*pp2; psm21:=mrl*pml+mr2*pm2;
g:=kll*ppl;
vs(tl,el2,n,psp21,g); vp(t2,al,ell);
vs(dell,tl,t2,l,dol);
g:=kl2*pp2; gg:=-psp21;
vs(tl,ell,n,gg,g); vp(t2,al,el2);
vs(del2,tl,t2,l,dol);
g:=-kll*ppl; gg:=-kl2*pp2;
vs(tl,ell,el2,g,gg); vp(t2,al,n);
vs(dn,tl,t2,l,dol); g:=k21*pml;
vs(tl,e22,n,psm21,g); vp(t2,a2,e21);
vs(t3,tl,t2,1,do2); vp(tl,a3,e21);
vs(de21,t3,tl,1,psgm);
g:=k22*pm2; gg:=-psm21;
vs(tl,e21,n,gg,g); vp(t2,a2,e22);
vs(t3,tl,t2,1,do2); vp(tl,a3,e22);
vs(de22,t3,tl,l,psgm);
vs(tl,ell,el2,ppl,pp2); vp(t2,al,rl);
vs(drl,tl,t2,l,dol);
for i:=l to 3 do dr2[i]:=drl[i]-dl[i];
mm2[l,5]:=-pl*np(dell,e21)-p2*np(del2,e21)
-mp(al,drl,e21)+m2*np(de22,e21)+psgm
*mp(a32,r2,e21)*u21+mp(a2,dr2,e21)*u21;
mm2[2,5]:=-pl*np(dell,e22)-p2*np(del2,e22)
-mp(al,drl,e22)+ml*np(de21,e22)+psgm
*mp(a32,r2,e22)*u21+mp(a2,dr2,e22)*u21;
pkll: =plI*ppl+pl2*pp2 ; pkl2 : =p21*pp-l+p22*pp2 ;
pk21:=mll*pml+ml2*pm2; pk22:=m21*pml+m22*pm2;
mm2[3,5]:=pkll*pl*cps+kll*pl*np(dell,e21)+pkl2
*p2*sps+kl2*p2*np(del2,e21)-pk21*ml-k22*m2
*np(de22,e21)+mp(o21,dn,e21)+psgm*np(a32,e22)*u21;
mm2[4,5]:=-pkll*pl*sps+kll*pl*np(dell,e22)+pkl2*p2
*cps+kl2*p2*np(del2,e22)-pk22*m2-k21*ml
*np(de21,e22)+mp(o21,dn,e22)-psgm*np(a32,e21)*u21;
eq4(mm2,pppl,ppp2,ppml,ppm2);
mtl[j,1]:=ppl;
mtl[j,2]:=pp2;
mtl[j,3]:=pml;
mtl[j,4]:=pm2;
mt2[j,l]:=(pl*pppl+p2*ppp2)/dsl;
mt2[ j , 2 ] : = (ml*ppml+m2*ppm2)/ds2;
mt2[j,3]:=(pl*ppp2-p2*pppl)/dsl/dsl+psp21;
mt2[j,4]:=(ml*ppm2-m2*ppml)/ds2/ds2+psm21;
vs(tl,ell,el2,pppl,ppp2); vs(t2,tl,dell,1,pl);
vs(t3,t2,del2,l,p2); vp(t2,al,drl);
vs(dfrl,t2,t3,l,1);
g:=-(pkll*pl+kll*pppl); gg:=-kll*pl;
v s ( t l , e l l , d e l l , g , g g ) ; g:=-(pkl2*p2+kl2*ppp2);
v s ( t 2 , t l , e l 2 , 1 , g ) ; gg:=-kl2*p2;
vs(t3,t2,del2,l,gg); vp(tl,al,dn);
vs(dfn,t3,tl,1,1);
mt2[j,5]:=(psgm*mp(a32,frl,n)*u21+mp(o21,dfrl,n)
+mp(o21,frl,dn)+psgm*mp(a32,r2,fn)*u21
+mp(a2,dr2,fn)*u21-mp(al,drl,fn)+np(v21,dfn)
+pu21*(psgm*np(a32,r2n)+mp(a2,dr2,n)
+mp(a2,r2,dn)))/gl;
dps:=psm21+do2*np(a2,n)+psgm*np(a3,n)-psp21-dol
*np(al,n);
g:=(4*dps*rm*(rm-rp*c2ps)-s2ps*(rp*(pk21-pk22)
-rm*(pkll-pkl2)))/g2;
gg:=g-dps;
mt2[j,6]:=g+psp21;
mt2[j,7]:=gg+psm21;
pg:= p k 2 1 * g 3 + p k 2 2 * g 4 - p k l l * g 5 - p k l 2 * g 6 + 2 * r p * g
*sin(2*lgl)-2*rm*gg*sin(2*lg2);
Pgg:=pk21*g4+pk22*g3-pkll*g6-pkl2*g5+2*rm*gg
*sin(2*lg2)-2*rp*g*sin(2*lgl);
mt2[j,8]:=-0.5*ll*pg/kdsl;
mt2[j,9]:=-0.5*12*pgg/kds2;
end;
^^ Υ * i T , e J . n ( 5fC SfC 5|C ?|C 3|C 3|C 3|C 3|C 3|C 3|C 3fC 5fi 3|C 3|C 3|C 3(C 3|C 3(C 5fC 3|C 3|C 3fC 3|C 5fC 3fC 3|C 5(C 9|C 3|C SfC 5|C 3|C 9|C 3fC 3|C 5(C 5fC 3|C 9|C «|C 3|C 3|C 3fC j
for i:=l to 4 do writeln(mtl[i,1],' ',mtl[i,2],' ',

mtl[i,3],· ',mtl[i,4]);
writeln('******************************************** )
for i:=l to 4 do writeln(mt2[i,1]:12,' ',mt2[i,2]:12,
' ',mt2[i,3]:12,' ',mt2[i,4]:12,' ',mt2[i,5]:12,' ',
mt2[i,6]:12,' ',mt2[i,7]:12,' ',mt2[i,8]:12,' ',
mt2[i,9]:12);
writeln('******************************************** )
end;
begin
assign(inf,'ct.dat'); reset(inf);
for i:=l to 49 do read(inf,ez[i]);
k:=-l; gama:=ez[48];
101:if k>0 then for i:=20 to 31 do ez[i]:=ez[i+12];
for i:=2 to 5 do write(ez[i],' ' ) ; writeln;
APPENDICES 199
for i:=10 to 13 do write!ez[i],' M ; writeln;
for i:=14 to 17 do write(ez[i],* ' ) ; writeln;
for i:=22 to 25 do write(ez[i],' ' ); writeln;
for i:=30 to 31 do write(ez[i],' *); writeln;
for i:=l to 8 do for j:=l to 40 do out[i,j]:=0;
for i:=l to 8 do out[i,41]:=le7;
ml :=sin(ez[15]*hd); m2 :=cos(ez[15]*hd);
m3 :=sin(ez[16]*hd); m4 :=cos(ez[16]*hd);
mml:=sin(ez[20]*hd); mm2:=cos(ez[20]*hd);
mm3:=sin(ez[21]*hd); mm4:=cos(ez[21]*hd);
mm5:=ez[8]*m4+ez[6]*m2-ez[9]*m2/ml;
mm6:=ez[8]*m3-ez[6]*ml;
u2c:=ez[13];
q[1]:=-m7*m6; q[2]:=m7*m5; q[3]:=m8;
gl:=ez[ll]*m8;
u21:=l/ez[7];
p[l]:=gl*m6+ez[10]; p[2]:=mm5-gl*m5;
p[3]:=mm6+ez[ll]*m7;
gl:=-(k*ez[ll]+ez[12]/2)*mm2/mml-mm6;
vs(jj,p,q,l,gl);
a[1]:=-m8*m6; a[2]:=m8*m5; a[3]:=-m7;
b[l]:=m5; b[2]:=m6; b[3]:=0;
h:=0; g2:=0;
a2c[l]:=0; a2c[2]:=m2; a2c[3]:=-ml;
gl:=ez[ll]+k*(ez[12]/2+mm6*mml/mm2);
lc2[l]:=ez[10]; lc2[2]:=-ez[9]*m2/ml; lc2[3]:=0;
ac[l]:=0; ac[2]:=0; ac[3]:=-l;
102:g3:=sin(g2); g4:=cos(g2 ) ; g5:=k*gl*mm2/mm1 ;
vs(sl,jj,q,l,g5); vs(s2,a,b,g4,g3);
vs(rf,si,s2,1,gl); g5:=k*mm2; g6:--mml;
vs(n,s2,q,g5,g6);
if ez[2]>0.5 then
begin
g7:=m2*(rf[3]+ezf9]);
g5:=u2c*(ri[2J*g7-n[l]*ez[10]*ml-n[3]*rf[2]*m2);
g6:=u2c*(n[l]*g7+n[2]*ez[10]*ml-n[3]*rf[l]*m2);
g7:=-(l-u2c*ml)*(n[2]*rf[l]-n[l]*rf[2])-ez[13]
*ez[10]*n[3]*m2;
g8:=arctan(g6/g5);
g9:=arctan(g7/sqrt(g5*g5+g6*g6-g7*g7));
if g5<0 then g9:=-g9;
g9:=g9-g8;
if abs(g5*sin(g9)+g6*cos(g9)-g7)>le-4 then
g9:=pi-g9-2*g8;
vr(re,rf,ac,g9)
end else for i:=l to 3 do re[i]:=rf[i];
h:=h+l; vs(r2c,re,lc2,1,-1);
gl0:=ez[28]*m2-ez[29]/ml-np(r2c,a2c);
vp(t,a2c,r2c); gll:=mv(t)-ez[28]*ml;
if (abs(glO)+abs(gll)X(ez[8]*7.45e-9 ) then goto 103;
case h of
1:begin
mat[l,3]:=gl0; mat[2,3]:=gll;
g2:=g2+0.0001; goto 102
end;
2:begin
mat[1,1]:=(gl0-mat[l,3])*10000;
mat[2,1]:=(gll-mat[2,3])*10000;
g2:=g2-0.0001;
gl:=gl+ez[28]/10000; goto 102
end;
3:begin
mat[1,2]:=(gl0-mat[l,3])*10000/ez[28];
mat[2,2]:=(gll-mat[2,3])*10000/ez[28];
eq(mat,g5,g6); h:=0;
gl:=gl*g6-ez[28]/10000;
g2:=g2-g5; goto 102
end
end;
103:g2:=-g3;
if ez(2]<0.5 then
{nongenerated member gear}
begin
vs(ec2,b,a,g4,g2);
for i:=l to 3 do nc[i]:=n[i]
end else
{generated member gear}
begin
vr(nc,n,ac,g9); vs(t,b,a,g4,g2); vr(ec2,t,ac,g9)
end;
vp(eel,ec2,nc); kc2:=-k*mm2/gl;
if ez[2]>0.5 then
begin
vp(p,a2c,r2c);
for i:=l to 3 do
for j:=l to 3 do dnc[i,j]:=-kc2*ec2[i]*ec2[j];
vp(t,ac,re);
vs(v2c,p,t,u2c, -1 ) ;
vs(o2c,a2c,ac,u2c,-1 ) ;
vtp(p,v2c,dnc); vp(jj,o2c,nc);
vs(p2c,p,jj,1,-1); g2:=mv(p2c);
for i:=l to 3 do t2[i]:=p2c[i]/g2;
vp(tl,t2,nc); vp(p,o2c,t); vp(jj,ac,v2c);
vs(q2c,p,jj,1,-1);
s2c:=np(nc,q2c)+np(v2c,p2c);
vtp(p,tl,dnc); gl:=-np(p,tl); vtp(jj,t2,dnc);
g2:=np(p2c,p2c)/s2c-np(jj,t2); g3:=-np(p,t2);
APPENDICES 201
bate:=-0.5*arctan(2*g3/(gl-g2)); g4:=-g3/sin(2*batc);
h2:=(gl+g2)/2;
k21:=h2+g4; k22:=h2-g4;
vr(e21,tl,nc,-bate); vr(e22,t2,nc,-bate)
end else
begin
for i:=l to 3 do
begin
e21[i] :=ecl[i]; e22[i]:=ec2[i]
end;
k21:=0; k22:=kc2; h2:=kc2/2
end;
g2:=ez[28]/m2-ez[29]/ml;
vs(t,a2c,r2c,g2,-1); vp(jj,nc,t); g3:=mv(jj);
for i:=l to 3 do lgth[i]:=-k*jj[i]/g3;
{longitudinal direction}
vp(por,lgth,nc);
{profile direction}
g2:=ez[29]/ml; vs(jj,a2c,r2c,g2,1);
for i:=l to 3 do jj[i]:=jj[i]/ez[28];
vp(b,lgth,jj); g2:=np(b,b)*m2/ml/ez[28];
dv(dn2,e21,e21,e22,e22,k21,k22);
g3:=mv(t);
for i:=l to 3 do t[i]:=t[i]/g3;
vtp(b,lgth,dn2); g3:=-np(b,lgth);
gl:=(g3*np(nc,t)-g2)*mp(nc, t,lgth);
{geodetic curvarure of longitudinal line}
h:=0;
if ez[2]<0.5 then
{third order geometric parameters of nongenerated
tooth surface}
begin
mll:=0; ml2:=0;
m21:=k*kc2*kc2*mml/mm2; m22:=0;
mrl:=0; mr2:=-m21/kc2
end else
{third order geometric parameters of generating flank}
begin
vp(b,a2c,r2c); vp(vc,ac,re);
for i:=l to 3 do v2[i]:=b[i]*u2c;
c21:=k*kc2*kc2*mml/mm2; cr2:=-c21/ke2;
{third order geometric parameters of generated
tooth surface}
togp(a2c,ac,nc,eel,ec2,e21,e22,v2,vc,v2c,o2c,p2c,tl,
kc2,k21,k22,c21,cr2,u2c,0,0,mll,ml2,m21,m22,mrl,mr2)
end;
b[l]:=l; b[2]:=0; b[3]:=0;
gl:=ez[15]*hd-pi/2; vr(rl,r2c,b,gl);
vr(jj,nc,b,gl); gl:=ez[14]*hd;
sgm:=sin(gl); cgm:=cos(gl);
g2:=jj[2]*(rl[3]+ez[3]-ez[4]*cgm)*sgm+jj[2]*ez[4]*cgm
*sgm-jj[l]*ez[5]*cgm-jj[3]*rl[2]*sgm;
g3:=jj[l]*(rl[3]+ez[3]-ez[4]*cgm)*sgm+jj[l]*ez[4]*cgm
*sgm+jj[2]*ez[5]*cgm-jj[3]*rl[l]*sgm;
g4:=-(u21+cgm)*(jj[l]*rl[2]-jj[2]*rl[l])
-jj[3]*ez[5]*sgm;
g5:=arctan(g3/g2);
g6:=arctan(g4/sqrt(g2*g2+g3*g3-g4*g4) )-g5;
if g2<0 then g6:=-g6-2*g5;
g6:=pi-g6-2*g5;
gl:=(ez[15]-ez[14])*hd;
vr(rl,r2c,b,gl ) ; vr(jj,nc,b,gl);
vr(p,e21,b,gl ) ; vr(q,e22,b,gl) ;
vr(a,lgth,b,gl); vr(t,por,b,gl);
a2[l]:=0; a2[2]:=cgm; a2[3]:=-sgm;
al[l]:=0; al[2]:=-l; al[3]:=0;
vr(r2,rl,a2,g6 ) ; vr(n,jj,a2,g6);
vr(e21,p,a2,g6); vr(e22,q,a2,g6);
vr(lgth,a,a2,g6); vrlpor,t,a2,g6);
l[l]:=-ez[5]; 1[2]:=ez[4]-ez[3]*cgm; 1[3]:=ez[3]*sgm;
vs(rl,r2,l,l,1);
{determination of the second order geometric parameters
of pinion tooth surface}
dv(dn2,e21,e21,e22,e22,k21,k22);
vs(t,por,lgth,mm4,mm3);
cmc:=np(t,e21); smc:=np(t,e22 ) ;
vs(o21,a2,al,u21,-l ) ; vp(vl,al,rl);
vp(p,a2,r2); for i:=l to 3 do v2[i]:=p[i]*u21;
vs(v21,v2,vl,l,-l ); vtp(q,t,dn2); du21:=ez[31];
ds2:=(du21*mp(a2,r2,n)-mp(o21,n,v2)+u21*mp(a2,n,v21))
/(mp(o21,n,t)-np(v21,q));
vs(dr,t,v2,ds2,1 ) ; vs(jj,dr,vl,1,-1) ;
dsl:=mv(jj);
for i:=l to 3 do
begin
p[i]:=jj[i]/dsl;
vsgm[i]:=(t[i]*ds2+jj[i])/2
end;
vp(a,a2,n);
vs(dn,q,a,ds2,u21);
vp(a,al,n); vs(b,dn,a,1,-1 ) ;
for i:=l to 3 do b[i]:=b[i]/dsl;
vtp(a,p,dn2); vs(jj,a,b,1,-1);
g2:=np(jj,por ) ; g3:=np(jj,lgth);
g4:=-arctan(g3/g2) ;
g7:=np(p,por); g8:=np(p,lgth);
104:g5:=8*ez[45]/sqr(ez[30]/cos(g4) ) ; kds2:=g5;
g6:=-arctan((g3 + g5*g8 )/(g2 + g5*g7 ) );
if abs(g4-g6)>le-15 then
begin
APPENDICES 203
g 4 : = g 6 ; g o t o 104
end;
skp:=sin(g6); ckp:=cos(g6);
12:=ez[30]/ckp;
kdsl:=(g3*skp-g2*ckp)/(g7*ckp-g8*skp);
kapa:=g6/hd; g 7 : = - n p ( p , b ) ;
vp(jj,η,ρ); g8:=-np(jj,b);
v t p ( q , j j , d n 2 ) ; g6:=-skp;
vs( tl,por,lgth,ckp,g6); vs(t2,por,lgth,skp,ckp);
vsgmp:=np(tl,vsgm);
ll:=sqrt(8*ez[45]/kdsl);
dv(dnc,tl,tl,t2,t2,kdsl,kds2);
vtp(a,j j,dnc); vs(b,q,a,1,-1);
g6:=-np(jj,b); g9:=-0.5*arctan(2*g8/(g7-g6));
hl:=(g6+g7)/2; glO:=-g8/sin(2*g9);
spc:=sin(g9); cpc:=cos(g9);
kll:=hl+gl0; kl2:=hl-gl0; g4:=-spc;
vs(ell,p,jj,cpc,g4); vs(el2,p,jj,spc,cpc);
slgl:=np(el2,tl); clgl:=np(ell,tl);
lgl:=arctan(slgl/clgl);
slg2:=np(e22,tl); clg2:=np(e21,tl);
if ez[l]<0.5 then
{optimization off}
begin
hsl:=8; af0:=ez[22];
muv:=ez[24]; muh:=ez[26];
saf:=sin(af0*hd); caf:=cos(af0*hd);
smuv:=sin(muv*hd); cmuv:=cos(muv*hd);
smuh:=sin(muh*hd); cmuh:=cos(muh*hd);
goto 108
end else
{optimization on}
for i:=l to 18 do read(inf,sez[i]);
for i:=l to 3 do write(sez[i],' M ; writeln;
for i:=4 to 6 do write(sez[i],' ' ) ; writeln;
hsl:=l;
af0:=0.2*ez[22]+0.8*ez[23];
muv:=0.2*ez[24]+0.8*ez[25];
muh:=0.2*ez[26]+0.8*ez[27];
goto 106;
105:if (abs(ez[23]-ez[22])'<0.01) and (hsl<6) then hsl: =6;
case hsl of
2:begin
af0:=0.8*ez[22]+0.2*ez[23];
muv:=0.2*ez[24]+0.8*ez[25];
muh:=0.2*ez[26]+0.8*ez[27]
end;
3:begin
af0:=0.8*ez[22]+0.2*ez[23];
muv:=0.8*ez[24]+0.2*ez[25];
muh:=0.2*ez[26]+0.8*ez[27]
end;
4:begin
af0:=0.8*ez[22]+0,2*ez[23];
muv:=0.2*ez[24]+0.8*ez[25];
muh:=0,8*ez[26]+0.2*ez[27]
end;
5:begin
af0:=0.8*ez[22]+0.2*ez[23];
muv:=0.8*ez[24]+0.2*ez[25];
rouh:=0.8*ez[26]+0.2*ez[27]2 * e z [ 2 7 ]
end;
6:begin
af0:=0.2*ez[22]+0.8*ez[23];
muv:=0.8*ez[24]+0.2*ez[25];
muh:=0.2*ez[26]+0.8*ez[27]
end;
7:begin
af0:=0.2*ez[22]+0.8*ez[23];
muv:=0.2*ez[24]+0.8*ez[25];
muh:=0.8*ez[26]+0.2*ez[27]
end;
8:begin
af0:=0.2*ez[22]+0.8*ez[23];
muv:=0.8*ez[24]+0.2*ez[25];
muh:=0.8*ez[26]+0.2*ez[27]
end
end;
106:hs2:=ez[46]; hs3:=0; hs4:=0;
10 7 : s a f : = s i n ( a f 0 * h d ) ; caf:=cos(af0*hd);
smuv:=sin(muv*hd); cmuv:=cos(muv*hd);
smuh:=sin(muh*hd); cmuh:=cos(muh*hd);
108:gl:=sin(ez[44]*hd);
{ c a l c u l a t i o n of machine s e t t i n g p a r a m e t e r s }
gamaf:=(ez[19]-muh)*hd+arctan(gl*smuv
/sqrt(cmuv*cmuv-gl*gl));
f[l]:=smuv; f[2]:=cmuv*smuh; f[3]:=-cmuv*cmuh;
g5:=cos(gamaf+muh*hd); g6:=sin(gamaf+muh*hd);
g2:=-n[3]*smuv-n[1]*cmuv*g5;
g3:=-n[1]*smuv+n[3]*cmuv*g5;
g4:=n[2]*cmuv*g6+saf;
if (g2*g2+g3*g3-g4*g4)<0 then
begin
i f g4<0 t h e n a f 0 : = a f 0 + h s 2 e l s e a f 0 : = a f 0 - h s 2 ;
g o t o 107
end;
i f g2<0 t h e n g 4 : = - g 4 ;
g5:=pi-arctan(g4/sqrt(g2*g2+g3*g3-g4*g4) )
-arctan(g3/g2);
g2:=cos(g5); g3:=sin(g5);
APPENDICES 205
m9:=sin(gamaf); mlO:=cos(gamaf);
dnc[l,l]:=g2; dnc[2,l]:=0; dnc[3,1]:=g3;
dnc[l,2]:=-g3*m9; dnc[2,2]:=mlO; dnc[3,2]:=g2*m9;
dncfl,3]:=-g3*mlO; dnc[2,3]:=-m9; dnc[3,3]:=g2*mlO;
vtp(nf,n,dnc); vtp(rlf,rl,dnc);
vtpiellf,ell,dnc); vtp(el2f,el2,dnc);
dv(dnc,ellf,ellf,el2f,el2f,kll,kl2);
af[l]:=0; af[2]:=0; af[3]:=-l;
vp(ef2,f,nf);
for i:=l to 3 do ef2[i]:=ef2[i]/caf;
vp(efl,ef2,nf); vtp(a,ef1,dnc);
g5:=-np(efl,a); g6:=-np(ef2,a); g7:=kll*kl2;
kf2:=g7/g5;
g9:=arctan(g5/g6); glO:=g5/sqr(sin(g9));
r:=caf/abs(kf2);
gl:=ez[19]*hd-gamaf; g2:=cos(gl);
g3:=sin(gl); g4:=rlf[3]*g2-rlf[2]*g3;
rpf:=r+k*g4*saf/(efl[3]*g2-efl[2]*g3)s
gll:= -g9·
vr(tfl,efl,nf,gll); vr(tf2,ef2,nf,gl1);
alf[l]:=0; alf[2]:=ml0; alf[3]:=-m9;
vp(jj,alf,rlf);
gl:=-ef2[3]/efl[3]; g2:=jj[3]/ef1[3];
g3:=kf2*sin(g9)/tf2[3]; g4:=-np(alf,tf2)/tf2[3];
vp(sl,alf,nf); vp(s2,nf,af);
Pl:=kf2*kf2+g3*g3*np(s2,s2)-2*g3*kf2*efl[3]+gl0*(kf2
+gl*g3*ef2[3]-g3*efl[3]);
P2:=2*(g3*g4*np(s2,s2)-kf2*np(alf,ef1)-g4*kf2*ef1[3]
+g3*np(sl,s2))+gl0*((g2*g3+gl*g4)*ef2[3]-g4*efl[3]
+g3*np(s2,jj));
p3:=g4*g4*np(s2,s2)+2*g4*np(sl,s2)+np(sl,sl)
+gl0*(g2*g4*ef2[3]+g4*np(s2,jj)+np(sl,jj));
if (p2*p2-4*pl*p3)<0 then
begin
muv:=muv*0.95; muh:=muh*0·95;
af0:=(20*af0+ez[22]+ez[23])/22; goto 107
end;
mu2:=-2*p3/(p2+sqrt(p2*p2-4*pl*p3));
mul:=mu2*gl+g2; uf1:=mu2*g3+g4; ulf:=l/ufl;
lfl[2]:=(jj[l]-mul*efl[l]-mu2*ef2[l])/ufl-rlf[2];
ep:=(jj[2]-mul*efl[2]-mu2*ef2[2])/ufl+rlf[l];
x:=-lfl[2]/ml0;
lfl[3]:=x*sin(gamaf); lfl[l]:=-ep;
vs(rf,rlf,If1,1,1); vp(si,f,ef2);
g8:=caf/kf2; g9:= -abs(rpf-r)*caf/saf;
vs(s2,sl,f,g8,g9);
fv:=ep-rlf[l]+s2[l]+ez[49]*f[l];
fh:=-x*ml0+rlf[2]-s2[2]-ez[49]*f[2];
sp:=sqrt(fv*fv+fh*fh);
qf:=-arctan(fh/fv)+pi/2;
ip:=arctan(-sqrt(f[l]*f[l]+f[2]*f[2])/f[3])/hd;
i f a b s ( f [ l ] ) > l e - 5 then
begin
jp:=(qf-arctan(f[2]/f[l]))/hd;
if f[l]<0 then jp:=jp+180
end
else if abs(f[2])>le-5 then
begin
jp:=(qf+arctan(f[l]/f[2]))/hd-90;
if f[2]<0 then jp:=jp+180
end
else jp:=0;
if jp<0 then jp:=jp+360;
xbp:=rlf[3]-s2[3]+x*m9-ez[49]*(l+f[3] );
vs(olf,alf,af,ulf,-1); vp(vf,af,rf);
vs(vlf,jj,vf,ulf,-1);
for i:=l to 3 do jj[i]:=jj[i]*ulf;
vp(s4,olf,nf);
gl:=-kf2*np(vlf,ef2);
for i:=l to 3 do plf[i]:=gl*ef2[i]-s4[i];
gl:=mv(plf); for i:=l to 3 do tf2[i]:=plf[i]/gl;
vp(tfl,tf2,nf);
{calculation of third order geometric parameters
f21:=-kf2*kf2*saf/caf; fr2:=-f21/kf2;
togp(alf,af,nf,efl,ef2,ellf,el2f,jj,vf,vlf,olf,
plf,tfl,kf2,kll,kl2,f21,fr2,ulf,0,0,
pll,pl2,p21,p22,prl,pr2);
{third order contact analysis}
tocam(al,a2,rl,r2,ell,el2,e21,e22,n,dr,dn,o21,u21,
du21,kll,kl2,k21,k22,cpc,spc,cmc,smc,pll,pl2,p21,p22,
prl,pr2,mll,ml2,m21,m22,mrl,mr2,dsl,ds2,slgl,clgl,
slg2,clg2,ll,12,kdsl,kds2,ddsl,dds2,ogl,og2,ql,q2,
dll,dl2,pol,po2,mol,mo2,ddu21);
{V and H check}
vh(al,a2,rl,r2,ell,el 2,e21,e22,n,dr,dn,lgth,o21,v21,
u21,du21,kll,kl2,k21,k22,pll,pl2,p21,p22,prl,pr2,mll,
ml2,m21,m22,mrl,mr2,ds2,gl,11,12,kdsl,kds2,slgl,clgl,
slg2,clg2,pol,po2,mol,mo2,gama,hd,dvv,dh,nues,
du21s,kps,11s,12s ) ;
if ez[l]<0.5 then goto 111;
{optimal synthesis}
gl:=sez[13]*sqr(sez[l]-og2)+sez[14]*sqr(sez[2]-dl2)
+sez[15]*sqr(sez[3]-ddu21)+sez[16]*sqr(sez[4]-nues)
+sez[17]*sqr(sez[5]-12s)+sez[18]*sqr(sez[6]-du21s)
+10*sqr(ez[25]-0.2-muv-abs(ez[25]-0.2-muv))
+10*sqr(ez[24]+0.2-muv+abs(ez[24]+0.2-muv))
+10*sqr(ez[27]-0.2-muh-abs(ez[27]-0.2-muh))
+10*sqr(ez[26]+0.2-muh+abs(ez[26]+0.2-muh))
+10*sqr(sez[8]-0.5-x-abs(sez[8]-0.5-x))
+ 10*sqr(sez[7]+0.5-x+abs(sez[7]+0.5-x ))
+10*sqr(sez[10]-0.5-ep-abs(sez[10]-0.5-ep))
APPENDICES 207
+10*sqr(sez[9]+0.5-ep+abs(sez[9]+0.5-ep));
if jp<180 then g3:=sez[ll] else g3:=sez[12];
gl:=gl+100*sqr(g3-0.2-ip-abs(g3-0.2-ip));
if (ez[23]-ez[22])>0.01 then
gl:=gl+50*sqr(ez[23]-0.2-af0-abs(ez[23]-0.2-af0))
+50*sqr(ez[22]+0.2-af0+abs(ez[22]+0.2-af0));
if hs4>0.5 then goto 111;
case hs3 of
0:begin
sul[l]:=muv; sul[2]:=muh; sul[3]:=af0;
sul[4]:=gl; hs3:=l;
for i:=l to 4 do su2[i]:=sul[i];
muv:=muv+hs2; goto 107
end;
l:if gl<su2[4] then ·
begin
su2[1]:=muv; su2[2]:=muh; su2[3]:=af0;
su2[4]:=gl; muh:=muh+hs2; hs3:=3; goto 107
end else
begin
muv:=muv-2*hs2; hs3:=2; goto 107
end;
2:if gl<su2[4] then
begin
su2[l]:=muv; su2[2]:=muh; su2[3]:=af0;
su2[4]:=gl; muh:=muh+hs2; hs3:=3; goto 107
end else
begin
muv:=muv+hs2; muh:=muh+hs2;
hs3:=3; goto 107
end;
3:if gl<su2[4] then
begin
su2[1]:=muv; su2[2]:=muh; su2[3]:=af0;
su2[4]:=gl;
if (ez[23]-ez[22])>0.01 then
begin
af0:=af0+hs2*cl; hs3:=5;
goto 107
end else goto 110
end else
begin
muh:=muh-2*hs2; hs3:=4; goto 107
end;
4:if gl<su2[4] then
begin
su2[1]:=muv; su2[2]:=muh; su2[3]:=af0;
su2[4]:=gl;
if (ez[23]-ez[221)>0.01 then
begin
af0:=af0+hs2*cl; hs3:=5; goto 107
end else goto 110
end else
if (ez[23]-ez[22])<0.01 then goto 109 else
begin
muh:=muh+hs2; af0:=af0+hs2*cl;
hs3:=5; goto 107
end;
5:if gl<su2[4] then
begin
su2[1]:=muv; su2[2]:=muh; su2[3]:=af0;
su2[4]:=gl; goto 110
end else
begin
af0:=af0-2*hs2*cl; hs3:=6; goto 107
end;
6:if gl<su2[4] then
begin
su2[1]:=muv; su2[2]:=muh;
su2[3]:=af0; su2[4]:=gl
end
end;
109:if su2[4]<sul[4] then goto 110;
if hs4=-l then
begin
muv:=su2[l]+hs2; muh:=su2[2]; af0:=su2[3];
hs3:=l; hs4:=0; goto 107
end;
if hs2<(ez[47]*2) then
begin
muv:=su2[l]; muh:=su2[2]; af0:=su2[3];
hs4:=l; goto 107
end else
begin
hs2:=hs2/10; muv:= su2[1]+hs2; muh:=su2[2];
af0:=su2[3]; hs3:=l; goto 107
end;
110:for i:=l to 3 do su3[i]:=2*su2[i]-sul[i];
for i:=l to 4 do sul[i]:=su2[i];
muv:=su3[l]+hs2; muh:=su3[2]; af0:=su3[3];
hs3:=l; hs4:=-l; goto 107;
lll:out[hsl,l]:=af0; out[hsl,2]:=ip; out[hsl,3]:=jp;
out[hsl,4]:=r; outfhsl,5]:=rpf; outfhsl,6]:=ulf;
outfhsl,7]:=x; outfhsl,8]:=xbp; outfhsl,9]:=sp;
out[hsl,10]:=qf; outfhsl,11]:=ep; outfhsl,12]:=gamaf;
out[hsl,13]:=ddsl; out[hsl,14]:=dds2; out[hsl,15]:=ogl;
out[hsl,16]:=og2; out[hsl,17]:=ql; out[hsl,18]:=q2;
out[hsl,19]:=dll; out[hsl,20]:=dl2; outfhsl,21]:=ddu21;
out[hsl,22]:=dvv; out[hsl,23]:=dh; out[hsl,24]:=nues;
out[hsl,25]:=du21s; out[hsl,26]:=kps; out[hsl,27]:=lls;
out[hsl,28]:=12s; out[hsl,29]:=pll; out[hsl,30]:=pl2;
out[hsl,31]:=p21; out[hsl,32]:=p22; out[hsl,33]:=prl;
outfhsl,34]:=pr2; out[hsl,35]:=mll; out[hsl,36]:=ml2;
outfhsl,37]:=m21; out[hsl,38]:=m22; out[hsl,39]:=mrl;
APPENDICES 209
out[hs1,40]:=mr2; out[hsl,41]:=gl;
if hsl<7.5 then
begin
hsl:=hsl+l; goto 105
end;
if ez[l]>0.5 then
begin
gl:=le9;
for i:=l to 8 do
if out[i,41]<gl then
begin
j:=i; gl:=out[i,41]
end
end else j:=8;
if k<0 then writeln('MACHINE SETTING (DRIVE SIDE)':47)
else writeln('MACHINE SETTING (REVERSE SIDE)':48);
writeln('Ep =':7,out[j,11],'X =*:7,out[j,7],
'Sp =':7,out[j,9],'Xbp =':7,out[j,8]);
w r i t e l n C u l f = ' : 7 , out [ j , 6] , ' q = ' : 7 , out [ j , 10 ] /hd,
'ip =':7,out[j,2],'jp =':7,out[j,3]);
writeln('gamaf =',out[j,12]/hd);
writeln('CUTTER PARAMETERS':42);
writeln('phi =':7,out[j,1],'Rp =':7,out[j,5],
'R =':7,out[j,4]);
writeln('CONTACT PARAMETERS':43);
writeln('dsl =':7,dsl,'ds2 =':7,ds2);
writeln('V(sigma) =',mv(vsgm),'V(sigma)p =':13,vsgmp);
w r i t e l n C l l =':7,11,'12 = ' : 7 ,12 , 'kapa =':8,kapa);
writeln('ddsl =':7,out[j,13],'dds2 =':7,out[j,14],
'Gl =':7,out[j,15],'G2 =':7,out[j,16]);
writeln('Ql =':7,out[j,17],'Q2 =':7,out[j,18],
'dll =':7,out[j,19],'dl2 =':7,out[j,20]);
writeln('ddu21 =':7,out[j,21]);
writeln('dv =':7,out[j,22],'dh =':7,out[j,23]);
writeln('d(nu)/ds* =':15,out[j,24],
'd(du21)/ds* =':15,out[j,25]);
writeln('d(kapa)/ds* =':15,out[j,26],'d(11)/ds* =':12,
out[j,27],'d(12)/ds* =':12,out[j,28]);
pll:=out[j,29]; pl2:=out[j,30]; p21:=out[j,31];
p22:=out[j,32]; prl:=out[j,33]; pr2:=out[j,34];
mll:=out[j,35]; ml2:=out[j,36]; m21:=out[j,37];
m22:=out[j,38]; mrl:=out[j,39]; mr2:=out[j,40];
{mounting error sensitivity analysis}
errsen(al,a2,rl,r2,dr,l,n,dn,ell,el2,e21,e22,o21,v21,
mil,ml2,m21,m22,mrl,mr2,dsl,ds2,pol,po2,mol,mo2,11,
12,lgl,kdsl,kds2);
if k=-l then
begin
k:=l; goto 101
end
end.
The input parameters of this program are listed below ·
ez[l]: 1 (Optimization o n ) , 0 (Optimization off) ;

ez[2]: 1 (Generated member gear), 0 (Nongenerated member gear);
ez[3]: The member gear root apex beyond the crossing point of axes:
ez[4]: The pinion root apex beyond the crossing point of axes·
ez[5]: Offset of the axes:
ez[6]: The member gear root apex beyond the pitch apex«
ez[7]: Gear ratio?
ez[8]: Mean pitch cone distance of the member gear;
ez[9]: Sliding base retreat for machining the member gear;
ez[lO]: Member gear blank offset;
ez[ll]: Mean cutter point radius of the alternate blade cutter for finishing the
member gear;
ez[l2]: Point width of the alternate blade cutter ;
ez[l3]: The ratio of roll for machining the member gear;
ez[l4]: Shaft angle of the gear pair;
ez[l5]: Root angle of the member gear;
ez[l6]: Dedendum angle of the member gear;
ez[l7]: Mean root cone spiral angle of the member gear;
ez[l8]: Normal tilt for machining the member gear;
ez[l9]: Root angle of the pinion;
ez[20]: Inside blade angle of the alternate blade cutter;
ez[2l]: Bias angle of the contact point path on gear flank (drive side);
ez[22]: Lower limit of the outside blade angle of the cutter for machining the
concave side of the pinion;
ez[23]: Upper limit of the outside blade angle of the cutter for machining the
ez[24]: Lower limit of vertical cutter tilt for machining the concave side of the
pinion;
ez[25]: Upper limit of vertical cutter tilt for machining the concave side of the
pinion;
ez[26]: Lower limit of horizontal cutter tilt for machining the concave side of
the pinion;
ez[27]: Upper limit of horizontal cutter tilt for machining the concave side of
the pinion;
APPENDICES 211
ez[28]: Reference cone distance for the convex side of the member gear;
ez[29]: The vertical distance between the reference cone for the convex side of
the member gear and the root cone;
ez[30]: Length of the projection of major axis of instantaneous contact ellipse
on the longitudinal direction of convex gear flank;
ez[3l]: Angular acceleration of the gear relative to the pinion (drive side);
ez[32]: Outside blade angle of the alternate blade cutter;
ez[33]: Bias angle of the contact point path on gear flank (reverse side);
ez[34]: Lower limit of the inside blade angle of the cutter for machining the
convex side of the pinion;
ez[35]: Upper limit of the inside blade angle of the cutter for machining the
ez[36]: Lower limit of vertical cutter tilt for machining the convex side of the
pinion;
ez[37]: Upper limit of vertical cutter tilt for machining the convex side of the
pinion;
ez[38]: Lower limit of horizontal cutter tilt for machining the convex side of
the pinion;
ez[39]: Upper limit of horizontal cutter tilt for machining the convex side of
the pinion;
ez[40]: Reference cone distance for the concave side of the member gear;
ez[4l]: The vertical distance between the reference cone for the concane side
of the member gear and the root cone;
on the longitudinal direction of concave gear flank;
ez[43]: Angular acceleration of the gear relative to the pinion (reverse side);
ez[44]: Mean spiral angle of the pinion;
ez[45]: Marking compound thickness;
ez[46]: Original step size of optimization;
ez[47]: Final step size of optimization;
ez[48]: Pitch angle of the pinion
ez[49]: The distance from the centre point of the cutter to the centre point of
tilt.
{If optimization is off, the following parameters are not necessary. }
sez[l]: Expected value ( E V ) of geodetic curvature of CPP on gear flank
(drive side);
sez[2]: EV of the rate of change of the length of contact field with respect to
the arc length of CPP on gear flank (drive side);
sez[3]: EV of the higher order angular acceleration of the gear to the pinion
(drive side);
sez[4]: EV of the rate of change of the direction of CPP on gear flank with
respect to the arc length of the longitudinal line of gear flank (drive
side);
the arc length of the longitudinal line of gear flank (drive side);
sez[6]: EV of the rate of change of the angular acceleration of the gear rela-
tive to the pinion with respect to the arc length of the longitudinal
line of gear flank (drive side);
sez[7]: Lower limit of the pinion root cone beyond the machine centre (drive
side);
sez[8]: Upper limit of the pinion root cone beyond the machine centre (drive
side);
sez[9]: Lower limit of pinion offset;
sez[lO] : Upper limit of pinion offset;
sez[ll] Upper limit of the tilt angle when swivel angle is less then 180°;
sez[l2] Upper limit of the tilt angle when swivel angle is larger then 180°;
sez[l3] sez[l8]: The corresponding weights of the the parameters, the EVs
of these parameters are expressed by s e z [ l ] - s e z [ 6 ] (drive
side);
sez[l]: Expected value (EV) of geodetic curvature of CPP on gear flank (re-
verse side);
the arc length of CPP on gear flank (reverse side);
(reverse side);
sez[4]: EV of the rate of change of the direction of CPP on gear flank with re-
spect to the arc length of the longitudinal line of gear flank (reverse
side);
the arc length of the longitudinal line of gear flank (reverse side);
tive to the pinion with respect to the arc length of the longitudinal line
APPENDICES 213
of gear flank (reverse side);
sez[7]: Lower limit of the pinion root cone beyond the machine centre (re-
verse side);
sez[8]: Upper limit of the pinion root cone beyond the machine centre (re-
verse side) ;
sez[9]: Lower limit of pinion offset;
sez[lO]: Upper limit of pinion offset;
s e z [ l l ] : Upper limit of the tilt angle when swivel angle is less then 180°;
sez[l2]: Upper limit of the tilt angle when swivel angle is larger then 180°;
sez[l3]-sez[l8]: The corresponding weights of the the parameters, the EVs
of these parameters are expressed by sez[l]-sez[6] (reverse
side);
3 MAIN PROGRAN FOR MACHINES WITH MODIFIED-ROLL MECHANISM
program mr(input»output) ;
label 101,102,103,104,105,106,107,108,109,110,111;
const cl=l.66666666667; hd=0.01745329252;
type
vectorl=array[1..44] of double;
matrixl=array[1·.2,1..3] of double;
matrix2=array[1..3,1.·3] of double;
matrix3=array[1.·4,1..5] of double;
matrix5=array[1..4,1..9] of real;
var
i,j,k,h,hsl,hs3,hs4,count:integer;
inf:text;
eztvectorl; sez:vector2;
al,a2,alf,a2c,ac,af,rl,r2,rlf,r2c,re,rf,n,nc,nf,cf,
ell,el2,e21,e22,ellf,el2f,e21c,e22c,ef1,ef2,eel,ec2,
vl,v2,vf,vc,v21,vlf,v2c,o21,olf,o2c,1,If1,lc2,dr,dn,
plf,p2c,q21,qlf,q2c,lgth,por,tl,t2,tfl,tf2,p,q,jj,t,
a,b,sul,su2,su3,sl,s2,s3,s4,vsgm:vector3;
kll,kl2,k21,k22,kf2,kc2,pll,pl2,p21,p22,prl,pr2,mll,
ml2,m21,m22,mrl,mr2,f21,fr2,c21,cr2,u21,du21,ddu21,
ulf,dulf,ddulf,ufl,dufl,u2c,du2c,ddu2c,kdsl,kds2,ll,
12,dsl,ds2,gama,gl,pol,po2,mol,mo2,lgl,slgl,clgl,
slg2,clg2,spc,cpc,smc,cmc,kapa,skp,ckp,bt,sbt,cbt,
bate,s2c,hl,h2,sgm,cgm,ddsl,dds2,ogl,og2,ql,q2,dll,
dl2,dvv,dh,nues,r,du21s,kps,11s,12s,fv,fh,sp,qf,eO,x,
afO,saf,caf,rpf,cmr,vsgmp,gl,g2,g3,g4,g5,g6,g7,g8,g9,
glO,gll,hs2,ml,m2,m3,m4,m5,m6,m7,m8,m9,ml0,mml,mm2,
mm3,mm4,mm5,mm6:double;
mat:matrix1; dnc,dn2:matrix2; out:matrix6;
begin
np:=a[l]*b[l]+a[2]*b[2]+a[3]*b[3]
end;
begin
mv:=sqrt(np(c,c))
end;
procedure vp(var d:vector3; e,f:vector3);
begin
d[l]:=e[2]*f[3]-e[3]*f[2];
d[2]:=e[3]*f[l]-e[l]*f[3];
d[3]:=e[l]*f[2]-e[2]*f[l]
end;
var j:vector3;
begin
vp(j,h,i); mp:=np(j, g)
end;
procedure vs(var k:vector3; l,m:vector3; a,b:double);
var i:integer;
begin
for i:=l to 3 do k[i]:= a*l[i]+b*m[i]
end;
procedure vr(var r:vector3; n,o:vector3; c:double);
var
i:integer; p,q:vector3;
pi,p2,p3,p4:double;
begin
pl:=np(n,o); p2:=cos(c); p3:=-pl*p2; p4:=sin(c);
vp(q,o,n); vs(p,o,q,p3,p4); vs(q,o,n,pl,p2);
end;
procedure dv(var s:matrix2; t,u,v,w:vector3; a,b:double);
var i,j:integer;
begin
for i:=l to 3 do
for j:=l to 3 do s[i,j]:=-a*t[i]*u[j]-b*v[i]*w[j]
end;
procedure vtpfvar x:vector3; y:vector3; z:matrix2);
var i,j:integer;
begin
x[i]:=0; for j:=l to 3 do x[i]:=x[i]+y[j]*z[j,i]
end
end;
procedure eq(atmatrixl; var cl,c2:double);
APPENDICES 215
var c3rdouble;
begin
c3:=a[l,l]*a[2,2]-a[l,2]*a[2,l];
cl:=(a[l,3]*a[2,2]-a[2,3]*a[l,2])/c3;
c2:=(a[l,l]*a[2,3]-a[2,l]*a[l,3])/c3
end;
var
i,j,k,n:integer;
x:vector4; p,trdouble;
begin
for k:=l to 4 do
begin
pr=0;
for ir=k to 4 do
begin
pr=a[i,k]; nr=i
end;
if n>k then
for j:=k to 5 do
begin
tr=a[k,j]; a[k,j]:=a[n,j]; a[n,j]r=t
end;
for jr=k+l to 5 do a[k,j]:=a[k,j]/p;
for ir=k+l to 4 do
for j:=k+l to 5 do
end;
kr=4;
repeat
tr=a[k,5];
for j:=k+l to 4 do tr=t-a[k,j]*x[j];
x[k]:=t; k:=k-l
until k=0;
blr=x[l]; b2r=x[2]; b3r=x[3]; b4r=x[4]
end;
{This procedure is for the calculation of third order
geometric parameters of generated tooth surface.}
procedure togp(al,af,n,ef1,ef2,ell,el2,vl,vf,vlf,olf,plf,
tlrvector3; kf2,kll,kl2,f21,fr2,ulf,dulf,ddulfrdouble;
var pll,pl2,p21,p22,prl,pr2rdouble);
var
i,j r integer;
fsl,fs2,fs21,fs32,g,cts,fssl,fss2,fss32,ps21,bts,cbt,
sbt,pss31,pss32,fol,pol,po2,cps,sps,fool,gl,g2,dl,d2:
double; efls,ef2s,ns,vlfs,plfs,nss,qlf,rfo,eflo,ef2o,
no,vlfo,qlfo,ηοο,si,s2,s3rvector3;
matrmatrixl; dnfs,dddrmatrix2;
begin
fslr=np(tl,efl); fs2r=np(tl,ef2);
fs21:=fr2*fs2; fs32:=kf2*fs2; g l : = - f s 2 1 ;
vs(ef2s,efl,n,gl,fs32) ;
f o r i : = l t o 3 do
begin
efls[i]:=fs21*ef2[i]; ns[i]:= -fs32*ef2[i]
end;
vp(vlfs,olf,tl); dv(ddd,ef2s,ef2,ef2,ef2s,l,l);
gl:=f21*fsl;
f o r i : = l t o 3 do
f o r j : = l t o 3 do
dnfs[i,j]:=kf2*ddd[i,j]-gl*ef2[i]*ef2[j];
vtp(sl,vlf,dnfs); vp(s2,olf,ns);
gl:=-np(vlfs,ef2)*kf2;
for i:=l to 3 do plfs[i]:=gl*ef2[i]+sl[i]-s2[i ] ;
g:=-np(plfs,tl)/mv(plf); cts:=g-fs21;
fssl:=-fs2*cts; fss2:=fsl*cts;
fss32:=f21*fsl*fs2+kf2*fss2;
gl:=-fss32; g2:=-fs32;
vs(nss,ef2,ef2s,gl,g2);
vp(sl,olf,vf ) ; vp(s2,af,vlf);
vs(s3,sl,s2,l,-l) ; gl:=dulf/ulf;
vs(qlf,s3,vl,l,gl);
fol:=np(n,qlf)/np(olf,ef2) ;
vs(rfo,efl,vf,fol,l);
cps:=np(ef1,ell); sps:*np(ef2,ell) ;
pol:=fol*cps-np(vlf,ell); po2:= -fol*sps-np(vlf,el2);
vp(eflo,af,efl); vp(ef2o,af,ef2);
vp(no,af,n); vp(sl,olf,rfo); g2:=ddulf/ulf;
vs(vlfo,vl,sl,gl,1) ;
vs(si,rfo,vf,1,1 ) ; vp(s2,al,si);
vs(s3,vl,s2,g2,dulf ) ;
vp(sl,af,rfo); vp(s2,olf,si ) ;
vs(sl,s3,s2,l,1 ) ; vp(s2,af,vlfo);
vs(qlfo,sl,s2,l,-l) ;
fool: = (np(no,qlf)+np(n,qlfo)-fol*(np(ef2o,olf )
+dulf*np(al,ef2)))/np(olf,ef2);
vp(noo,af,no);
dl:=kll*(ulf*mp(al,ellfvlf)-fool*cps+fol*sps
*np(olf,n)+np(vlfo,ell))+ulf*(mp(al,no,ell)+kl2
*po2*np(al,n))+dulf*np(al,el2)-np(noo,ell);
d2:=kl2*(ulf*mp(al,el2,vlf)+fool*sps+fol*cps
*np(olf,n)+np(vlfolel2))+ulf*(mp(al,no,el2)-kll
*pol*np(al,n))-dulf*np(al,ell)-np(noo,el2);
cbt:=np(tl,ell); sbt:=np(tl,el2);
mat[l,3]:=pol*pol*(kll*g*sbt-np(nss,ell))-dl*cbt*cbt;
mat[2,3]:=po2*po2*(kl2*g*cbt+np(nss,el2))+d2*sbt*sbt;
gl:=pol*sbt-po2*cbt;
mat[1,1]:=2*pol*cbt*gl;
mat[1,2]:=sqr(pol*sbt)-sqr(po2*cbt);
mat[2,l]:=mat[l,2];
mat[2,2]:=2*po2*sbt*gl;
APPENDICES 217
for i:=l to 2 do
for j:=l to 3 do mat[i,j]:=mat[i,j]/100;
eq(mat,pl2,p21);
pll:=(dl-2*pl2*pol*po2-p21*po2*po2)/sqr(pol);
p22:=(d2-pl2*pol*pol-2*p21*pol*po2)/sqr(po2);
prl:=P12/(kll-kl2); pr2:=p21/(kll-kl2)
end;
{This procedure is for the analysis of the third order
contact parameters of mismatched tooth surfaces.}
procedure tocam(al,a2,rl,r2,ell,el2,e21,e22,n,dr,dn,o21:
vector3; u21,du21,kll,kl2,k21,k22,cpc,spc,cmc,smc,pll,
pl2,p21,p22,prl,pr2,mll,ml2,m21,m22,mrl,mr2,dsl,ds2,
slgl ,clgl ,slg2,clg2,ll ,12,kdsl ,kds2-.double ; var ddsl,
dds2,gl,g2,ql,q2,dll,dl2,pol,po2,mol,mo2,ddu21:double);
var
dell ,del2,de21 , de22 , ddn, ddr, si, s2 , s3-.vector 3 ;
dkll,dkl2,dk21,dk22,po21,mo21»pool,poo2,mool,moo2,
dct,pa21,ma21,cps,sps,c2ps,s2ps,dps,dlgl,dlg2,dl,d2,
d3,d4:double; matimatrixl;
begin
pol:=cpc*dsl; po2:=spc*dsl;
mol:=cmc*ds2; mo2:=smc*ds2;
po21:=prl*pol+pr2*po2; mo21:=mrl*mol+mr2*mo2;
vp(si,al,ell); dl:=kll*pol; vs(s2,si,n,1,dl);
vs(dell,el2,s2,po21,l);
vp(sl,al,el2); dl:=kl2*po2;
d2:=-po21; vs(s2,si,n,1,dl);
vs(del2,ell,s2,d2,l);
pa21:=po21+np(al,n); ma21:=mo21+np(a2,n)*u21;
dkll:=pll*pol+pl2*po2; dkl2:=p21*pol+p22*po2;
dk21: =mll*mol+ml2*mo2 ; dk22 : =m21*mol+m22*mo2 ;
vs(sl,dr,dn,k21,1); vs(s2,dr,dn,k22,1);
mat[1,3]:=mo2*(k22-k21)*ma21-dk21*mol+mp(o21,sl,e21)
+(k21*mp(a2,r2,e21)+np(a2,e22))*du21+cps*((k21-kl2)
*po2*pa21+dkll*pol)+sps*((kll-k21)*pol*pa21+dkl2
*po2);
mat[2,3]:=mol*(k22-k21)*ma21-dk22*mo2+mp(o21,s2,e22)
+(k22*mp(a2,r2,e22)-np(a2,e21))*du21+sps*((kl2-k22)
*po2*pa21-dkll*pol)+cps*((kll-k22)*pol*pa21+dkl2
*po2);
mat[1,1]:=(k21-kl1)*cps;
mat[1,2]:=(k21-kl2)*Sps;
mat[2,1]:=(kll-k22)*sps;
mat[2,2]:=(k22-kl2)*cps;
eq(mat »pool,poo2);
mool:=mo2*ma21-mp(o21,dr,e21)-mp(a2,r2,e21)*du21+cps
*(pool-po2*pa21)+sps*(poo2+pol*pa21);
moo2:=-mol*ma21-mp(o21,dr,e22)-mp(a2,r2,e22)*du21-sps
*(pool-po2*pa21)+cps*(poo2+pol*pa21);
ddsl:=cpc*pool+spc*poo2; dds2:=cmc*mool+smc*moo2;
gl:=((pol*poo2-po2*pool)/dsl/dsl+po21)/dsl;
g2:=((mol*moo2-mo2*mool)/ds2/ds2+mo21)/ds2;
dl:=-dkll*pol-kll*pool; d2:=-kll*pol;
vs(sl,ell,dell,dl,d2);
dl:=-dkl2*po2-kl2*poo2; d2:=-kl2*po2;
vs(s2,el2,del2,dl,d2); vs(s3,si,s2 , 1 ,1 ) ;
vp(si,al,dn); vs(ddn,s3,si,1 ,1 ) ;
vs(si,ell,de11,ροοΐ,pol); vs(s2,el2,de12,poo2,po2);
vs(s3,si,s2,1,1 ) ; vp(si,al,dr); vs(ddr,si,s3,1,1);
dl:=2*du21; vs(si,ddn,dn,u21,dl);
ddu21:=( nip ( o21, ddr, n) + 2*mp (o21 , dr,dn) —mp( al, r 1,ddn)
+mp(a2,r2,sl)+2*mp(a2,dr,n)*du21)/mp(a2,n,r2);
dps:=ma21-pa21;
dl:=(kll-kl2)/2; d2:=(k21-k22)/2;
dlgl:=(4*dps*d2*(d2-dl*c2ps)-(dl*(dk21-dk22)-d2*(dkll
-dkl2))*s2ps)/(4*(dl*dl+d2*d2-2*dl*d2*c2ps));
dlg2:=dlgl-dps;
ql:=(dlgl+po21)/dsl; q2:=(dlg2+mo21)/ds2;
d3:=dk21*clg2*clg2+dk22*slg2*slg2-dkll*clgl*clgl-dkl2
*slgl*slgl+4*dl*slgl*clgl*dlgl-4*d2*slg2*clg2*dlg2;
d4:^dk21*slg2*slg2+dk22*clg2*clg2-dkll*slgl*slgl-dkl2
*clgl*clgl-4*dl*slgl*clgl*dlgl+4*d2*slg2*clg2*dlg2;
dll:=-0.5*ll*d3/kdsl/ds2; dl2:=-0.5*12*d4/kds2/ds2
end;
{This procedure is for the analysis of the changing rates
of contact situations under V and H check.}
procedure vh(al,a2,rl,r2,ell,el2,e21,e22,n,dr,dn,lgth,
o21,v21:vector3; u21,du21,kll,kl2,k21,k22,pll,pl2,p21,
p2 2,prl,pr2,mll,ml2,m21,m22,mrl,mr2,ds2,gl,11,12,dkl,
dk2,slgl,clgl,slg2,clg2,pol,po2,mol,mo2,gama,hd:double;
var dv,dh,nues,du21s,kps,11s,12s:double ) ;
var
i:integer;
ksl,ks2,ks3,ells,el2s,e21s,e22sfns,ns2,rls,r2s,ls,
drls,dns,sl,s2,s3,s4:vector3;
psl,ps2,msl,ms2,pols,po2s,mols,mo2s,cps,sps,c2ps,
s2ps,pss,ps21,ms21,lgls,lg2s,klls,kl2s,k21s,k22s,
dkls,dk2s,rols,ro2s,gl,g2,g3,g4,g5,g6,g7:double;
mat:matrix3;
begin
vp(si,a2,al); gl:=mv(sl);
for i:=l to 3 do ksl[i]:=sl[i]/gl;
vp(si,ksl,al); gl:=sin(gama*hd); g2:=cos(gama*hd);
vs(ks2,sl,al,gl,g2); vp(ks3,ksl,ks2);
msl:=np(lgth,e21 ) ; ms2:=np(lgth,e22);
g3:=-k21*msl; g4:=-k22*ms2;
vs(ns2,e21,e22,g3,g4) ;
mat[l,l]:=np(ell,ks3);
mat[1,2]:=np(el2,ks3);
mat[1,3]:=mp(al,rl,ks3);
APPENDICES 219
mat[1,4]:=-mp(a2,r2,ks3);
mat[l,5]:=np(lgth,ks3);
mat[2,l]:=-kll;
mat[2,2]:=0;
mat[2,3]:=np(al,el2);
mat[2,4]:=-np(a2,el2);
mat[2,5]:=np(ns2,ell);
mat[3,1]:=0;
mat[3,2]:=-kl2;
mat[3,4]:=np(a2,ell);
mat[3,5]:=np(ns2,el2);
mat[4,l]:=np(al,el2);
vp(si,al,rl);
mat[4,3]:=mp(al,n,si);
mat[4,4]:=-mp(a2,n,si);
mat[4,5]:=u21*mp(a2,n,lgth)-np(v21,ns2 );
eq4(mat,psl,ps2,rols,ro2s);
vs(s2,ell,el2,psl,ps2); vs(rls,si,s2,rols,1);
vp(s2,a2,r2); vs(r2s,lgth,s2,1,ro2s);
vs(ls,rls,r2s,1,-1);
dv:=np(ls,ksl); dh:=np(Is,ks2)*g2;
ps21:=prl*psl+pr2*ps2; ms21:=mrl*msl+mr2*ms2;
gl:=kll*psl; g2:=kl2*ps2;
vs(sl,el2,n,ps21,gl); vp(s2,al,ell);
vs(ells,si,s2,l,rols); g3:=-ps21;
vs(sl,ell,n,g3,g2); vp(s2,al,el2);
vs(el2s,sl,s2,l,rols);
g3:=-kll*psl; g4:=-kl2*ps2;
vs(sl,ell,el2,g3,g4); vp(s2,al,n);
vs(ns,si,s2,1,rols);
g3:=k21*msl; g4:=k22*ms2;
vs(sl,e22,n,ms21,g3); vp(s2,a2,e21);
vs(e21s,sl,s2,l,ro2s); gl:=-ms21;
vs(sl,e21,n,gl,g4); vp(s2,a2,e22);
mat[l,1]:=-np(ell,e21);
mat[l,2]:=-np(el2,e21);
mat[1,3]:=1;
mat[1,4]:=0;
vs(sl,ells,el2s,pol,po2);
mat[l,5]:=np(sl,e21)+mp(al,rls,e21)-mo2*np(e22s,e21)
-u21*mp(a2,r2s,e21);
mat[2,l]:=-mat[l,2];
mat[2,2]:=mat[l,1];
mat[2,3]:=0;
mat[2,4]:=1;
mat[2,5]:=np(si,e22)+mp(al,rls,e22)-mol*np(e21s,e22)
-u21*mp(a2,r2s,e22);
mat[3,1]:=-kl1*mat[1,1];
mat[3,2]:=-kl2*mat[1,2];
mat[3,3]:=-k21;
mat[3,4]:=0;
k l l s : = p l l * p s l + p l 2 * p s 2 ; kl2s:=p21*psl+p22*ps2;
k21s:=mll*msl+ml2*ms2; k22s:=m21*msl+m22*ms2;
mat[3,5]:=k21s*mol+k22*mo2*np(e22s,e21)+mat[l,l]*klls
*pol-kll*pol*np(ells,e21)+mat[l,2]*kl2s*po2
-kl2*po2*np(el2s,e21)-mp(o21,ns,e21) ;
mat[4,1]:=kll*mat[l,2];
mat[4,2]:= -kl2*mat[1,1];
mat[4,3]:=0;
mat[4,4]:=-k22;
mat[4,5]:=k22s*mo2+k21*mol*np(e21s,e22)-mat[1,2]*klls
*pol-kll*pol*np(ells,e22)+mat[l,l]*kl2s*po2
eq4(mat,pols,po2s,mols,mo2s);
gl:=(mol*mo2s-mo2*mols)/ds2/ds2; nues:=gl-gl+ms21;
vs(sl,ell,el2,pols,po2s); vs(s2,ells,el2s,pol,po2);
vs(s3,si,s2,1,1) ; vp(s4,al,rls); vs(drls,s3,s4,1,1) ;
gl:=-klls*pol-kll*pols; g2:=-kll*pol;
vs(sl,ell,ells,gl,g2) ;
g3:=-kl2s*po2-kl2*po2s; g4:=-kl2*po2;
vs(s2,el2,el2s,g3,g4 ) ; vp(s3,al,ns);
vs(s4,sl,s2,l,l); vs(dns,s3,s4,1,1);
du21s:=(mp(o21,drls,n)+mp(o21,dr,ns)+np(v21,dns)
-mp(al,rls,dn)+u21*mp(a2,r2s,dn)+du21*(mp(a2,r2s,n)
+mp(a2,r2,ns)))/mp(a2,n,r2);
gl:=(kll-kl2)/2; g2:=(k21-k22)/2;
g3:=ps21+np(al,n)*rols; g4:=ms21+np(a2,n)*ro2s;
pss:=g4-g3; cps:=np(ell,e21); sps:=np(el2,e21);
Igls:=(4*pss*g2*(g2-gl*c2ps)-s2ps*(gl*(k21s-k22s)
-g2*(klls-kl2s)))/4/(gl*gl+g2*g2-2*gl*g2*c2ps);
lg2s:=lgls-pss; kps:=gl-lg2s~ms21;
g3:=clgl*clgl; g4:=slgl*slgl;
g5:=clg2*clg2; g6:=slg2*slg2;
g7:=4*(gl*clgl*slgl*lgls-g2*clg2*slg2*lg2s);
dkls:=k21s^g5+k22s*g6-klls*g3-kl2s*g4+g7;
dk2s:=k21s*g6+k22s*g5-klls*g4-kl2s*g3-g7;
lls:=-0.5*ll*dkls/dkl; 12s:=-0.5*12*dk2s/dk2
end;
{This procedure is for the analysis of error sensitivity
of the contact situations with respect to misalignments.
However, it is not necessary for optimal synthesis.}
procedure errsen(al,a2,rl,r2,frl,l,n,fn,ell,el2,e21,e22,
o21,v21:vector3; u21,pu21,kll,kl2,k21,k22,pll,pl2,p21,
p22,prl,pr2,mil,ml2,m21,m22,mrl,mr2,dsl,ds2,pl,p2,ml,
m2,ll,12,lgl,kdsl,kds2:double);
var
i,j:integer;
a3,dell,del2,de21,de22,drl,dr2,dn,dl,a32,r2n,dfrl,
dfn,tl,t2,t3:vector3;
APPENDICES 221
dol,do2,ρρΐ,pp2,pml,pm2,sgm,cgm,psgm,dps,sps,cps,s2ps,
c2ps,lg2,pppl,ppp2,ppml,ppm2,rp,rm,psp21,psm21,pkl1,
pkl2,pk21,pk22,gl,g2,g3,g4,g5,g6,g,gg,pg,pgg:double;
mml,mm2:matrix3;
mtl:matrix4; mt2:matrix5;
begin
vp(a3,al,a2); sgm:=mv(a3);
for i:=l to 3 do a3[i]:=a3[i]/sgm;
cgm:=np(al,a2); cps:=np(ell,e21); sps:=np(el2,e21);
s2ps:=2*sps*cps; c2ps:=cps*cps-sps*sps;
lg2:=lgl-arctan(sps/cps); rp:=(kll-kl2)/2;
rm:=(k21-k22)/2; vp(a32,a3,a2); vp(r2n,r2,n);
gl:=-np(a2,r2n); g2:=4*(rp*rp+rm*rm--2*rp*rm*c2ps);
g3:=sqr(cos(lg2)); g4:=sqr(sin(lg2));
g5:=sqr(cos(lgl)); g6:=sqr(sin(lgl));
mml[1,1]:=0;
mml[1,2]:=0;
mml[1,3]:=mp(al,rl,n);
mml[l,4]:=gl;
mml[2,1]:=(k21-kl1)*eps;
mml[2,2]:=(k21-kl2)*sps;
mml[2,3]:=k21*mp(al,rl,e21)+np(al,e22) ;
mml[2,4]:=-np(a2,e2 2)-k21*mp( a2 , r 2 , e 21 ) ;
mml[3,1]:=(kll-k22)*sps;
mml[3,2]:=(k22-kl2)*cps;
mml[3,3]:=k22*mp(al,rl,e22)-np(al,e21);
mml[3,4]:=np(a2,e21)-k22*mp(a2,r2,e22);
mml[4,1]:=kll*np(v21,ell)+np(o21,el2);
mml[4,2]:=kl2*np(v21,el2)-np(o21,ell);
mml[4,3]:=np(o21,al)*np(n,rl)-np(o21,rl)*np(n,al)
+mp(al,v21,n);
mml[4,4]:=0;
mm2[1,1]:=cps;
mm2[1,2]:=sps;
mm2[l,3]:=-l;
mm2[l,4]:=0;
mm2[2,1]:=-sps;
mm2[2,2]:=cps;
mm2[2,3]:=0;
mm2[2,4]:=-l;
mm2[3,l]:=-kll*cps;
mm2[3,2]:=-kl2*sps;
mm2[3,3]:=k21;
mm2[3,4]:=0;
mm2[4,l]:=kll*sps;
mm2[4,2]:=-kl2*cps;
mm2[4,3]:=0;
mm2[4,4]:=k22;
for j:=l to 4 do
begin
case j of
1:begin
for i:=l to 3 do dl[i]:=al[i]; psgm:=0
end;
2:begin
for i:=l to 3 do dl[i]:=a2[i]; psgm:=0
end;
3:begin
for i:=l to 3 do dl[i]:=a3[i]; psgm:=0
end;
4:begin
g:=np(l,a2)+np(l,a32)*cgm/sgm;
for i:=l to 3 do dl[i]:=g*a32[i]; psgm:=l
end
end;
mml[1,5]:=psgm*np(a3,r2n)+np(dl,n);
mml[2,5]:=psgm*(np(a3,e22)+k21*mp(a3,r2,e21))
+k21*np(dl,e21);
mml[3,5]:=psgm*(-np(a3,e21)+k22*mp(a3,r2,e22))
+k22*np(dl,e22);
mml[4,5]:=u21*(psgm*np(a32,r2n)-mp(a2,dl,n));
eq4(mml,ppl,pp2,dol,do2);
pml:= ppl*cps+pp2*sps+dol*mp(al,rl,e21)-do2
pm2:=-ppl*sps+pp2*cps+dol*mp(al,rl,e22)-do2
psp21:=prl*ppl+pr2*pp2; psm21:=mrl*pml+mr2*pm2;
g:=kll*ppl; vs(tl,el2,n,psp21,g); vp(t2,al,ell);
vs(dell,tl,t2,1,dol); g:=kl2*pp2; gg:=-psp21;
vs(tl,ell,n,gg,g) ; vp(t2,al,el2);
vs(del2,tl,t2,l,dol);
g:=-kll*ppl; gg:=-kl2*pp2;
vs(tl,ell,el2,g,gg) ; vp(t2,al,n);
vs(dn,tl,t2,l,dol); g:=k21*pml;
vs(tl,e22,n,psm21,g); vp(t2,a2,e21);
vs(t3,tl,t2,l,do2 ) ; vp(tl,a3,e21);
vs(de21,t3,tl,l,psgm);
g:=k22*pm2; gg:=-psm21;
vs(tl,e21,n,gg,g); vp(t2,a2,e22);
vs(t3,tl,t2,l,do2); vp(tl,a3,e22);
vs(de22,t3,tl,1,psgm);
vsitl,ell,el2,ppl,pp2); vp(t2,al,rl);
vs(drl,tl,t2,l,dol);
for i:=l to 3 do dr2[i]:=drl[i]-dl[i];
mm2[l,5]:=-pl*np(dell,e21)-p2*np(de12,e21)
-mp(al,drl,e21)+m2*np(de22,e21)+psgm
*mp(a32,r2,e21)*u21+mp(a2,dr2,e21)*u21;
mm2[2,5]:=-pl*np(del1,e22)-p2*np(del2,e22)
-mp(al,drl,e22)+ml*np(de21,e22)+psgm
*mp(a3 2,r2,e22)*u21+mp(a2,dr2,e22)*u21;
pkll:=pll*ppl+pl2*pp2; pkl2:=p21*ppl+p22*pp2;
pk21:=mll*pml+ml2*pm2; pk22:=m21*pml+m22*pm2;
mm2[3,5]:=pkll*pl*cps+kll*pl*np(dell,e21)+pkl2*p2
*sps+kl2*p2*np(del2,e21)-pk21*ml-k22*m2
APPENDICES 223
*np(de22,e21)+mp(o21,dn,e21)+psgm*np(a32,e22)*u21;
mm2[4,5]:=~pkll*pl*sps+kll*pl*np(dell,e22)+pkl2*p2
*cps+kl2*p2*np(del2,e22)-pk22*m2-k21*ml
*np(de21,e22)+mp(o21,dn,e22)-psgm*np(a32,e21)*u21;
eq4(mm2,pppl,ppp2,ppml,ppm2);
mtl[j,1]:=ppl;
mtl[j,2]:=pp2;
mtl[j,3]:=pml;
mtl[j,4]:=pm2;
mt2[j,1]:=(pl*pppl+p2*ppp2)/dsl;
mt2[j,2]:=(ml*ppml+m2*ppm2)/ds2;
mt2[j,3]:=(pl*ppp2-p2*pppl)/dsl/dsl+psp21;
mt2[j,4]:=(ml*ppm2-m2*ppml)/ds2/ds2+psm21;
vs(tl,ell,el2,ρρρΐ,ppp2); vs(t2,tl,dell,l,pl);
vs(t3,t2,del2,l,p2) ; vp(t2,al,drl);
vs(dfrl,t2,t3,l,l ) ;
g:=-(pkll*pl+kll*pppl); gg:=-kll*pl;
vs(tl,ell,dell,g,gg) ; g:=-(pkl2*p2+kl2*ppp2);
vs(t2,11,el2,1,g ) ; gg:= -kl2*p2;
vs(t3,t2,del2,1,gg) ; vp(tl,al,dn);
vs(dfn,t3,tl,l,l);
mt2[j,5]:=(psgm*mp(a32,frl,n)*u21+mp(o21,dfrl,n)
+mp(o21,frl,dn)+psgm*mp(a32,r2,fn)*u21
+mp(a2,dr2,fn)*u21-mp(al,drl,fn)+np(v21,dfn)
+pu21*(psgm*np(a32,r2n)+mp(a2,dr2,n)
+mp(a2,r2,dn)))/gl;
dps:=psm21+do2*np(a2,n)+psgm*np(a3,n)-psp21-dol
*np(al,n);
g:=(4*dps*rm*(rm-rp*c2ps)-s2ps*(rp*(pk2l-pk22)
-rm*(pkll-pkl2)))/g2;
gg:=g-dps;
mt2[j,6]:=g+psp21;
mt2[j,7]:=gg+psm21;
pg:= pk21*g3+pk22*g4-pkll*g5-pkl2*g6+2*rp*g
*sin(2*lgl)-2*rm*gg*sin(2*lg2 ) ;
Pgg:=pk21*g4+pk22*g3-pkll*g6-pkl2*g5+2*rm*gg
*sin(2*lg2)-2*rp*g*sin(2*lgl);
mt2[j,8]:=-0.5*ll*pg/kdsl;
mt2[j,9]:=-0.5*12*pgg/kds2;
end;
w p i t p I T\ I 3fC 3|C 3fC 3|C 9|C 3fC «|C 9|C 3fC 3|C 9|C 3fC 3fC 3|C 3fC 3fC 3|C 3§C 3fC 9|C SfC 3|C 3fC dfC 3|C 3|C 3fC 9fC 3|C 3|C 3|C 3fC 9fC 3fC 3|C 9fC ?|C 9fC 3fC 3|C 3|C 3fC I *
for i:=l to 4 do writeln(mtl[i,1],' ',mtl[i,2],' ',

mtl[1,3],' ',mtl[i,4]);
W r i t e l n ( * ***4c**^**^*^*******3#:^*****^^***^**5|C3*ia|c*3|c34c3|c3|c » ) j
for i:=l to 4 do writeln(mt2[i,1]:12,' ',mt2[i,2]:12,
' ',mt2[i,3]:12,' ',mt2[i,4]:12,' ',mt2[i,5]:12,
' ',mt2[i,6]:12,' ',mt2[i,7]:12,' ',mt2[i,8]:12,
• ',mt2[i,9]:12);
jfl T* 1 1 e 1 Π ( 9|C 9|C 3fC 3|C 9fC 3fC 3fC 3(C 3fC 3fC 9fC 3fC 9fC 3fC 9|C 3fC 3fC SfC 9|C 3fC 3fC 3fC 3fC 9|C 3fC 3|C 3|C 3fC )|C 3|C 3fC 3fC 3fC 3fC SfC 3(C 3|C 3fC 3fC 3|C 3fC 3fC ι
end;
begin
assign( inf,'mr.dat'); reset(inf);
for i:=l to 44 do
begin
read(inf,ez[i]);
end;
k:=-l; gama:=ez[44];
101:if k>0 then for i:=20 to 29 do ez[i]:=ez[i+10];
for i:=6 to 9 do write(ez[i],' * ) ; writeln;
for i:=10 to 13 do write(ez[i],' ' ); writeln;
fro i;=22 to 25 do write(ez[i],' ' ) ; writeln;
for i:=l to 4 do for j:=l to 38 do out[i,j]:=0;
for i:=l to 4 do out[i,39]:=le7;
ml :=sin(ez[15]*hd); m2 :=cos(ez[15]*hd);
m9 :=sin(ez[19]*hd); mlO:=cos(ez[19]*hd);
mml:=sin(ez[20]*hd); mm2:=cos(ez[20]*hd);
mm3:=sin(ez[21]*hd); mm4:=cos(ez[21]*hd);
mm5:=ez[8]*m4+ez[6]*m2-ez[9]*m2/ml;
mm6:=ez[8]*m3-ez[6]*ml;
u2c:=ez[13] ;
q[1]:=-m7*m6; q[2]:=m7*m5; q[3]:=m8;
gl:=ez[ll]*m8; u21:=l/ez[7];
p[l]:=gl*m6+ez[10]; p[2]:=mm5-gl*m5;
p[3]:=mm6+ez[ll]*m7;
gl:=-(k*ez[11]+ez[12]/2)*mm2/mml-mm6;
vs(jj,p,q,l,gl);
a[1]:=-m8*m6; a[2]:=m8*m5; a[3]:=-m7;
b[l]:=m5; b[2]:=m6; b[3]:=0;
h:=0;
g2:=0;
a2c[l] :=0; a2c[2]:=m2; a2c[3]:=-ml;
gl:=ez[ll]+k*(ez[12]/2+mm6*mml/mm2);
lc2[l]:=ez[10]; lc2[2]:=-ez[9]*m2/ml; lc2[3]:=0;
ac[l]:=0; ac[2]:=0; ac[3]:=-l;
102:g3:=sin(g2); g4:=cos(g2); g5:=k*gl^mm2/mml;
vs(sl,jj,q,l,g5) ; vs(s2,a,b,g4,g3);
vs(rf,si,s2,1,gl) ; g5:=k*mm2; g6:=-mml;
vs(n,s2,q,g5,g6);
if ez[2]>0.5 then
begin
g7:=m2*(rf[3]+ez[9] );
g5:=u2c*(n[2]*g7-n[l]*ez[10]*ml-n[3]*rf[2]*m2);
g6:=u2c*(n[l]*g7+n[2]*ez[10]*ml-n[3]*rf[l]*m2);
g7:=-(l-u2c*ml)*(n[2]*rf[l]-n[l]*rf[2])-ez[13]
*ez[10]*n[3]*m2;
APPENDICES 225
g8:=arctan(g6/g5);
g9:=arctan(g7/sqrt(g5*g5+g6*g6-g7*g7));
if g5<0 then g9:=-g9; g9:=g9-g8;
g9:=pi-g9-2*g8;
vr(re,rf,ac,g9)
end else
for i:=l to 3 do rc[i]:=rf[i];
h:=h+l; vs(r2c,re,lc2,1,-1);
gl0:=ez[26]*m2-ez[27]/ml-np(r2c,a2c);
vp(t,a2c,r2c); gll:=mv(t)-ez[26]*ml;
if (abs(glO)+abs(gll)) <(ez[8]*7.45e-9) then goto 103;
case h of
1:begin
mat[l,3]:=gl0; mat[2,3]:=gll;
g2:=g2+0.0001; goto 102
end;
2:begin
mat[l,l]:=(gl0-mat[l,3])*10000;
mat[2,1]:=(gll-mat[2,3])*10000;
g2:=g2-0.0001; gl:=gl+ez[26]/10000;
goto 102
end;
3:begin
mat[1,2]:=(gl0-mat[l,3])*10000/ez[26];
mat[2,2]:=(gll-mat[2,3])*10000/ez[26];
eq(mat,g5,g6); h:=0;
gl:=gl-g6-ez[26]/10000;
g2:=g2-g5; goto 102
end
end;
103:g2:=-g3;
if ez[2]<0.5 then
begin
vs(ec2,b,a,g4,g2);
for i:=l to 3 do nc[i]:=n[i]
end else
begin
vr(nc,n,ac,g9); vs(t,b,a,g4,g2); vr(ec2,t,ac,g9)
end;
vp(eel,ec2,nc);
kc2:=-k*mm2/gl;
if ez[2]>0.5 then
begin
vp(p,a2c,r2c);
for i:=l to 3 do
for j:=l to 3 do dnc[i,j]:=-kc2*ec2[i]*ec2[j];
vp(t,ac,rc) ;
vs(v2c,p,t,u2c,-1) ;
vs(o2c,a2c,ac,u2c,-1) ;
vtp(p,v2c,dnc); vp(jj,o2c,nc);
vs(p2c,p,jj,1,-1); g2:=mv(p2c);
for i:=l to 3 do t2[i]:=p2c[i]/g2;
vp(tl,t2,nc); vp(p,o2c,t); vp(jj,ac,v2c);
vs(q2c,p,jj,1,-1);
s2c:=np(nc,q2c)+np(v2c,p2c);
vtp(p,tl,dnc); gl:=-np(p,tl ) ;
vtp(jj,t2,dnc); g2:=np(p2c,p2c)/s2c-np(jj,t2);
g3:=-np(p,t2);
batc:=-0.5*arctan(2*g3/(gl-g2) ) ;
g4:=-g3/sin(2*batc); h2:=(gl+g2)/2;
k21:=h2+g4; k22:=h2-g4;
vr(e21,tl,nc,-bate); vr(e22,t2,nc,-bate)
end else
begin
for i:=l to 3 do
begin
e21[i]:=ecl[i]; e22[i]:=ec2[i]
end;
k21:=0; k22:=kc2; h2:=kc2/2
end;
g2:=ez[26]/m2-ez[27]/ml;
vs(t,a2c,r2c,g2,-l); vp(jj,nc,t); g3:=mv(jj);
for i:=l to 3 do lgth[i]:=-k*jj[i]/g3;
{longitudinal direction}
vp(por,lgth,nc);
{profile direction}
g2:=ez[27]/ml; vs(jj,a2c,r2c,g2,1) ;
for i:=l to 3 do jj[i]:=jj[i]/ez[26];
vp(b,lgth,jj); g2:=np(b,b)*m2/ml/ez[26];
g3:=mv(t); for i:=l to 3 do t[i]:=t[i]/g3;
dv(dn2,e21,e21,e22,e22,k21,k22);
vtp(b,lgth,dn2); g3:=-np(b,lgth);
gl:=(g3*np(nc,t)-g2)/mp(nc1t,lgth);
{geodetic curvature of longitudinal line}
h:=0;
if ez[2]<0.5 then
{third order geometric parameters of nongenerated
member gear tooth surface}
begin
mll:=0; ml2:=0; m21:=k*kc2*kc2*mml/mm2;
m22:=0; mrl:=0; mr2:=-m21/kc2
end else
{third order geometric parameters of generating flank}
begin
du2c:=0; ddu2c:=0; vp(b,a2c,r2c);
vp(vc,ac,re); for i:=l to 3 do v2[i]:=b[i]*u2c;
c21:=k*kc2*kc2*mml/mm2; cr2:=-c21/kc2;
APPENDICES 227
{third order geometric parameters of generated
member gear tooth surface}
togp(a2c,ac,nc,ecl,ec2,e21,e22,v2,vc,v2c,o2c,
p2c,tl,kc2,k21,k22,c21,cr2,u2c,du2c,ddu2c,
mil,ml2,m21,m22,mrl,mr2)
end;
b[l]:=l; b[2]:=0; b[3]:=0;
gl:=ez[15]*hd-pi/2; vr(rl,r2c,b,gl);
vr(jj,nc,b,gl); gl:=ez[14]*hd;
sgm:=sin(gl); cgm:=cos(gl);
g2:=jj[2]*(rl[3]+ez[3]-ez[4]*cgm)*sgm+jj[2]*ez[4]*cgm
*sgm-jj[l]*ez[5]*cgm-jj[3]*rl[2]*sgm;
g3:=jj[l]*(rl[3]+ez[3]-ez[4]*cgm)*sgm+jj[l]*ez[4]*cgm
*sgm+jj[2]*ez[5]*cgm-jj[3]*rl[l]*sgm;
g4:=-(u21+cgm)*(jj[l]*rl[2]-jj[2]*rl[l])-jj[3]*ez[5]
*sgm; g5:=arctan(g3/g2);
g6:=arctan(g4/sqrt(g2*g2+g3*g3-g4*g4))-g5;
if g2<0 then g6:=-g6-2*g5;
g6:=pi-g6-2*g5;
gl:=(ez[15]-ez[14])*hd;
vr(rl,r2c,b,gl); vr(jj,nc,b,gl);
vr(p,e21,b,gl); vr(q,e22,b,gl);
vr(a,lgth,b,gl); vr(t,por,b,gl);
a2[l]:=0; a2[2]:=cgm; a2[3]:=-sgm;
al[l]:=0; al[2]:=-l; al[3]:=0;
vr(r2,rl,a2,g6); vr(n,jj,a2,g6);
vr(e21,p,a2,g6); vr(e22,q,a29g6);
vr(lgth,a,a2,g6); vr(por,t,a2,g6);
l[l]:=-ez[5]; 1[2]:=ez[4]-ez[3]*cgm; 1[3]:=ez[3]*sgm;
vs(rl,r2,1,1,1);
{determination of the second order geametric para-
meters of pinion tooth surface}
dv(dn2,e21,e21,e22,e2 2,k21,k22);
vs(t,por,lgth,mm4,mm3);
cmc:=np(t,e21); smc:=np(t,e22);
vs(o21,a2,al,u21,-1); vp(vl,al,rl); vp(p,a2,r2);
for i:=l to 3 do v2[i]:=p[i]*u21;
vs(v21,v2,vl,1,-1); vtp(q,t,dn2); du21:=ez[29];
ds2:=(du21*mp(a2,r2,n)-mp(o21,n,v2)+u21*mp(a2,n,v21))
/(mp(o21,n,t)-np(v21,q));
vs(dr,t,v2,ds2,1); vs(jj,dr,vl,1,-1); dsl:=mv(jj);
for i:=l to 3 do
begin
p[i]:=jj[i]/dsl; vsgm[i]:=(t[i]*ds2+jj[i])/2
end;
vp(a,a2,n); vs(dn,q,a,ds2,u21);
vp(a,al,n); vs(b,dn,a,1,-1);
for i:=l to 3 do b[i]:=b[i]/dsl;
vtp(a,p,dn2); vs(jj,a,b,l,-l);
g2:=np(jj,por); g3:=np(jj,lgth); g4:=-arctan(g3/g2);
g7:=np(p,por); g8:=np(p,lgth);
104:g5:=8*ez[41]/sqr(ez[28]/cos(g4) ); kds2:=g5;
g6:=-arctan((g3+g5*g8)/(g2+g5*g7 ) ) ;
if abs(g4-g6)>le-15 then
begin
g4:=g6; goto 104
end;
skp:=sin(g6); ckp:=cos(g6);
12:=ez[28]/ckp;
kdsl:=(g3*skp-g2*ckp)/(g7*ckp-g8*skp);
kapa:=g6; g7:=-np(p,b); vp(jj,n,p);
g8:=-np(jj,b); vtp(q,jj,dn2);
vs(tl,por,lgth,ckp,-skp); vs(t2,por,lgth,skp,ckp);
vsgmp:=np(tl,vsgm); 11:=sqrt(8*ez[41]/kdsl);
dv(dnc,tl,tl,t2,t2,kdsl,kds2);
vtp(a,jj,dnc); vs(b,q,a,1,-1);
g6:=-np(jj,b); g9:=-0.5*arctan(2*g8/(g7-g6));
hl:=(g6+g7)/2; glO:=-g8/sin<2*g9);
spc:=sin(g9); cpc:=cos(g9);
kll:=hl+gl0; kl2:=hl-gl0;
vs(ell,p,jj,cpc,-spc); vs(el2,p,jj,spc,cpc);
slgl:=np(el2,tl); clgl:=np(ell,tl);
lgl:=arctan(slgl/clgl) ;
slg2:=np(e22,tl); clg2:=np(e21,tl);
if ez[l]<0.5 then
{optimization off)
begin
hsl:=4; af0:=ez[22]; e0:=ez[24];
saf:=sin(af0*hd); caf:=cos(af0*hd);
goto 108
end else
{optimization on}
for i:=l to 14 do read(inf,sez[i] ) ;
for i:=l to 3 do write(sez[i ] ) ;
writeln;
for i;=12 to 14 do write(sez[i],' ' ) ; writeln;
hsl:=l;
e0:=0.2*ez[24]+0.8*ez[25] ;
af0:=0.2*ez[22]+0.8*ez[23] ;
goto 106;
105:if abs(ez[23]-ez[22]X0.01 then hsl:=4;
case hsl of
2:begin
e0:=0.2*ez[24]+0.8*ez[25] ;
af0:=0.8*ez[22]+0.2*ez[23]
end;
3 tbegin
e0:=0.8*ez[24]*0,2'*ez[25];
af0:=0.2*ez[22]+0.8*ez[23]
APPENDICES 229
end;
4 :begin
e0:=0.8*ez[24]+0.2*ez[25];
af0:=0.8*ez[22]+0.2*ez[23]
end
end;
106:hs2:=ez[42]; hs3:=0; hs4:=0;
10 7 : s a f : = s i n ( a f 0 * h d ) ; c a f : = c o s ( a f 0 * h d ) ;
{ c a l c u l a t i o n of m a c h i n e setting p a r a m e t e r s }
108:g2:=-n[l]*ml0; g3:=n[3]*mlO; g4:=saf+n[2]*m9;
if ( g 2 * g 2 + g 3 * g 3 - g 4 * g 4 ) < 0 t h e n
begin
if g4<0 t h e n a f O : = a f O + h s 2 e l s e a f 0 : = a f 0 - h s 2 ;
goto 107
end;
if g 2 < 0 t h e n g 4 : = - g 4 ;
g5:=pl-arctan(g4/sqrt(g2*g2+g3*g3-g4*g4))
-arctan(g3/g2);
g2:=cos(g5); g3:=sin(g5);
dnc[l,l]:=g2; dnc[2,l]:=0; dnc[3,1]:=g3;
dnc[1,2]:=-g3*m9; dnc[2,2]:=ml0; dnc[3,2]:=g2*m9;
dnc[l,3]:=-g3*ml0; dnc[2,3]:=-m9; dnc[3,3]:=g2*ml0;
vtp(nf,n,dnc); vtp(rlf,rl,dnc);
vtp(ellf,ell,dnc); vtp(el2f,el2,dnc);
dv(dnc,ellf,ellf,el2f,el2f,kll,kl2);
af[l]:=0; af[2]:=0; af[3]:=-l;
vp(ef2,af,nf);
for i:=l to 3 do e f 2 [ i ] : = e f 2 [ i ] / c a f ;
vp(ef1,ef2,nf); vtp(a,ef1,dnc);
g5:=-np(efl,a); g6:=-np(ef2,a);
g7:=kll*kl2; kf2:=g7/g5;
g9:=arctan(g5/g6); glO:=g5/sqr(sin(g9));
r:=caf/abs(kf2); rpf:=r+k*rlf[3]*saf/caf;
g 11: = - g 9 ;
vr(tfl,efl,nf,gll); vr(tf2,ef2,nf,gll);
alf[l]:=0; alf[2]:=ml0; alf[3]:=-m9;
vp(jj,alf,rlf); g2:=jj[3]/caf;
g3:=kf2*sin(g9)/tf2[3];
g4:=-np(alf,tf2)/tf2[3]; lfl[l]:=-e0;
rf[l]:=rlf[l]+lfl[l]; vp(si,alf,nf);
gl:=(jj[2]-g2*efl[2]-g4*(e0-rlf[l]))/
(g3*(e0-rlf[l])+ef2[2]);
ufl:=gl*g3+g4; ulf:=l/ufl;
Ifl[2]:=(jj[l]-g2*efl[l]-gl*ef2[l])/ufl-rlf[2];
x:=-lfl[2]/ml0; If1[3]:=x*m9;
rf[2]:=rlf[2]+lfl[2]; rf[3]:=rlf[3]+lf1[3];
vp(s2,af,nf); vs(plf,si,s2,-1,g4);
vs(vlf,efl,ef2,g2,gl); vp(vf,af,rf);
dufl:=-(np(plf,plf)-gl0*(np(vlf,plf)-ufl*np(sl,vf)
+ufl*np(s2,jj)))/gl0/np(nf,vf);
cmr:=dufl*ez[40]/ufl/ufl;
fv:=rf[l]+k*r*ef2[2]; fh:=rf[2]-k*r*ef2[1];
sp:=sqrt(fv*fv+fh*fh); qf:=arctan(fh/fv)+pi/2;
vs(olf,alf,af,ulf,-l); vs(vlf,jj,vf,ulf,-1);
for i:=l to 3 do jj[i]:=jj[i]*ulf;
vp(s4,olf,nf ); gl:= -kf2*np(vlf,ef2 ) ;
for i:=l to 3 do plf[i]:=gl*ef2[i]-s4[i ] ;
dulf:=-dufl*ulf*ulf*ulf;
ddulf:=-3*dufl*dulf*ulf*ulf;
f21:=-kf2*kf2*saf/caf;
fr2:=-f21/kf2; gl:=mv(plf);
for i:=l to 3 do tf2[i]:=plf[i]/gl;
vp(tfl,tf2,nf);
{calculation of third order geometric parameters
togp(alf,af,nf,ef1,ef2,ellf,el2f,jj,vf,vlf,olf,
plf,tfl,kf2,kll,kl2,f21,fr2,ulf,dulf»ddulf,
pll,pl2,p21,p22,prl,pr2 ) ;
{third order contact analysis}
tocam(al,a2,rl,r2,ell,el2,e21te22,n,dr,dn,o21,u21,
du21,kll,kl2,k21,k22,cpc,spc,cmc,smc,pll,pl2,p21,
p22,prl,pr2,mll,ml2,m21,m22,mrl,mr2,dsl,ds2,slgl,
clgl,slg2,clg2,ll,12,kdsl,kds2,1,ddsl,dds2,ogl,og2,
ql,q2,dll,dl2,pol,po2,mol,mo2,ddu21 ) ;
{V and H check}
vh(al,a2,rl,r2,ell,el2,e21,e22,n,dr,dn,lgth,o21,v21,
mil,ml2,m21,m22,mrl,mr2,ds2,gl,11,12,kdsl,kds2,
slgl,clgl,slg2,clg2,pol,po2,mol,mo2,gama,hd,dvv,dh,
nues,du21s,kps,11s,12 s ) ;
if ez[l]<0.5 then goto 111;
{optimal synthesis}
gl:=sez[9]*sqr(sez[1]-og2)+sez[10]*sqr(sez[2]-dl2)
+sez[11]*sqr(sez[3]-ddu21)+sez[12]*sqr(sez[4]-nues)
+sez[13]*sqr(sez[5]-12s)+sez[14]*sqr(sez[6]-du21s)
+10*sqr(ez[25]-0.5-e0-abs(ez[25]-0.5-e0))
+ 10*sqr(ez[24]+0.5-e0 + abs(ez[24]+0.5-e0 ) )
+10*sqr(sez[8]-0.5-x-abs(sez[8]~0.5-x))
+10*sqr(sez[7]+0.5-x+abs(sez[7]+0.5-x));
if (ez[23]-ez[22])>0.01 then
gl:=gl+50*sqr(ez[23]-0,2-af0-abs(ez[23]-0.2-af0))
+50*sqr(ez[22]+0.2-af0+abs(ez[22]+0.2-af0));
if hs4>0.5 then goto 111;
case hs3 of
0:begin
sul[l]:=e0; sul[2]:=af0; sul[3]:=gl; hs3:=l;
for i:=l to 3 do su2[i]:=sul[i];
e0:=hs2+e0; goto 107
end;
l:if gl<su2[3] then
begin
su2[1]:=e0; su2[2]:=af0; su2[3]:=gl;
APPENDICES 231
if (ez[23]-ez[22])>0.01 then
begin
afO:=afO+hs2*cl; hs3:=3; goto 107
end else goto 110
end else
begin
eO:=eO-2*hs2; hs3:=2; goto 107
end;
2:if gl<su2[3] then
begin
su2[l]:=e0; su2[2]:=af0; su2[3]:=gl;
if (ez[23]-ez[22])>0.01 then
begin
hs3:=3; af0:=af0+hs2*cl; goto 107
end else goto 110
end else
if (ez[23]-ez[22])<0.01 then goto 109 else
begin
eO:=e0+hs2; af0:=af0+hs2*cl;
hs3:=3; goto 107
end;
3:if gl<su2[3] then
begin
su2[1]:=e0; su2[2]:=af0; su2[3]:=gl;
goto 110
end else
begin
afO:=afO-2*hs2*cl; hs3:=4; goto 107
end;
4:if gl<su2[3] then
begin
su2[l]:=e0; su2[2]:=af0; su2[3]:=gl
end
end;
if su2[3]<sul[3] then goto 110;
109:if hs4=-l then
begin
e0:=su2[l]+hs2; af0:=su2[2];
hs3:=l; hs4:=0; goto 107
end;
if hs2<(ez[43]*2) then
begin
e0:=su2[l]; af0:=su2[2];
hs4:=l; goto 107
end else
begin
hs2:=hs2/10; eO:=su2[1]+hs2;
af0:=su2[2]; hs3:=l; goto 108
end;
110:for i:=l to 3 do
begin
su3[i]:=2*su2[i]-sul[i]; sul[i]:=su2[i]
end;
e0:=su3[l]+hs2; afO:=su3[2];
hs3:=l; hs4:=-l; goto 107;
lll:out[hsl,l]:=e0; out[hsl,2]:=af0; out[hsl,3]:=r;
out[hsl,4]:=rpf; out[hsl,5]:=ulf; out[hsl,6]:=x;
out[hsl,7]:=lfl[3]; out[hsl,8]:=cmr; out[hsl,9]:=sp;
out[hsl,10]:=qf; out[hsl,11]:=ddsl; out[hsl,12]:=dds2;
out[hsl,13]:=ogl; out[hsl,14]:=og2; out[hsl,15]:=ql;
out[hsl,16]:=q2; out[hsl,17]:=dll; out[hsl,18]:=dl2;
out[hsl,19]:=ddu21; out[hsl,20]:=dvv; out[hsl,21]:=dh;
out[hsl,22]:=nues; out[hsl,23]:=du21s;
out[hsl,24]:=kps; out[hsl,25]:=lls; out[hsl,26]:=12s;
out[hsl,27]:=pll; out[hsl,28]:=pl2; out[hsl,29]:=p21;
out[hsl,30]:=p22; out[hsl,31]:=prl; out[hsl,32]:=pr2;
out[hsl,33]:=mll; out[hsl,34]:=ml2; out[hsl,35]:=m21;
out[hsl,36]:=m22; out[hsl,37]:=mrl; out[hsl,38]:=mr2;
out[hsl,39]:=gl;
if hsl<3,5 then
begin
hsl:=hsl+l; goto 105
end;
if ez[l]>0.5 then
begin
gl:=le9;
for i:=l to 4 do
if out[i,39]<gl then
begin
gl:=out[i,39]
end
end else j:=4;
if k<0 then writeln('MACHINE SETTING (DRIVE SIDE)*:47)
else writeln('MACHINE SETTING (REVERSE SIDE)':48);
writeln('Ep = ' : 7 ,out [ j , 1 ] , 'X =':7,out[j,6],
'ulf =':7,out[j,5],'Cmr =':7,out[j,8]);
writeln('gamaf =',ez[19],'Sp =':7,out[j,9],
'q =':7,out[j,10]/hd,'Xbp =':7,out[j,7]);
writelni'CUTTER PARAMETERS':42);
writeln('phi =':7,out[j,2],'Rp =':7,out[j,4],
'R =':7,out[j,3]);
writeln('CONTACT PARAMETERS':43);
writelnf'dsl =':7,dsl,'ds2 =':7,ds2);
writeln('V(sigma) =',mv(vsgm),'V(sigma)p =':13,vsgmp);
writelnCll =':7,11,'12 = ' : 7 ,12 , ' kapa = ' : 8 , kapa/hd) ;
writeln('ddsl =':7,out[j,11],'dds2 =':7,out[j,12],
'Gl =':7,out[j,13],'G2 =':7,out[j,14]);
writeln('Ql =':7,out[j,15],'Q2 =':7,out[j,16],
'dll =':7,out[j,17],'dl2 =':7,out[j,18]);
writeln('ddu21 =·:7,out[j,19]);
writeln('dV =':7,out[j,20],'dH =':7,out[j,21] ) ;
APPENDICES 233
writeln('d(nu)/ds* = ':15,out[j,22],
'd(du21)/ds* = ':15,out[j,23]);
writeln('d(kapa)/ds* =':15,out[j,24],'d(11)/ds* = ':
12,out[j,25],'d(12)/ds* =':12,out[j,26]);
pll:=out[j,27]; pl2:=out[j,28];
p21:=out[j,29]; p22:=out[j,30];
prl:=out[j,31]; pr2:=out[j,32];
mll:=out[j,33]; ml2:=out[j,34];
m21:=out[j,35]; m22:=out[j,36];
mrl:=out[j,37]; mr2:=out[j,38];
{mounting error sentivity analysis}
errsenfal,a2,rl,r2,dr,l,n,dn,ell,el2,e21,e22,o21,v21
mil,ml2,m21,m22,mrl,mr2,dsl,ds2,pol,po2,mol,mo2,11,
12,lgl,kdsl,kds2);
if k=-l then
begin
k:=l;
goto 101
end
end.
The input parameters of this program are listed below :
ez[l]: 1 (Optimization o n ) , 0 (Otimization off);

ez[2]: 1 (Generated member g e a r ) , 0 (Nongenerated member g e a r ) ;
ez[3]: The rpember gear root apex beyond the crossing point of a x e s :
ez[4]: The pinion root apex beyond the crossing point of a x e s :
ez[5]: Offset of the axes :
ez[6]s The member gear root apex beyond the pitch a p e x :
ez[7]s Gear ratio;
ez[8]: Mean pitch cone distance of the member gear;
ez[9]s Sliding base retreat for machining the member gear;
ez[lO]: Member gear blank offset;
ez[ll]: Mean cutter point radius of the alternate blade cutter for finishing the
member gear;
ez[l2]s Point width of the alternate blade cutter;
ez[l3]s The ratio of roll for machining the member gear;
ez[l4]: Shaft angle of the gear pair;
ez[l5]: Root angle of the member gear;
ez[l6]: Dedendum angle of the member gear;
ez[l7]: Mean root cone spiral angle of the member gear;
ez[l8]: Normal tilt for machining the member gear;
ez[l9]s Root angle of the pinion?
ez[20]s Inside blade angle of the alternate blade cutter;
ez[2l]: Bias angle of the contact point path on gear flank (drive s i d e ) ;
ez[22]s Lower limit of the outside blade angle of the cutter for machining the
ez[23]: Upper limit of the outside blade angle of the cutter for machining the
ez[24]: Lower limit of pinion blank offset for machining the concave side of
the pinion;
ez[25]: Upper limit of pinion blank offset for machining the concave side of
the pinion;
ez[26]: Reference cone distance for the convex side of the member gear;
ez[27]: The vertical distance between the reference cone for the convex side of
the member gear and the root cone;
on the longitudinal direction of convex gear flank;
ez[29]: Angular acceleration of the gear relative to the pinion (drive s i d e ) ;
ez[30]: Outside blade angle of the alternate blade cutter;
ez[3l]s Bias angle of the contact point path on gear flank (reverse s i d e ) ;
ez[32]s Lower limit of the inside blade angle of the cutter for machining the
ez[33] : Upper limit of the inside blade angle of the cutter for machining the
ez[34]: Lower limit of pinion blank offset for machining the convex side of the
pinion;
ez[35] : Upper limit of pinion blank offset for machining the convex side of the
pinion;
ez[36]: Reference cone distance for the concave side of the member gear;
ez[37]: The vertical distance between the reference cone for the concave side
of the member gear and the root cone;
ez[38]s Length of the projection of major axis of instantaneous contact ellipse
on the longitudinal direction of concave gear flank;
ez[39]: Angular acceleration of the gear relative to the pinion (reverse side) ;
ez[40]: A constant of machine tool;
APPENDICES 235
ez[4l]: Marking compound thickness;

ez[42]: Original step size of optimization;
ez[43]: Final step size of optimization;
ez[44]: Pitch angle of the pinion;
sez[l]: Expected value ( E V ) of geodetic curvature of CPP on gear flank
(drive s i d e ) ;
the arc length of CPP on gear flank (drive s i d e ) ;
(drive s i d e ) ;
spect to the arc length of the longitudinal line of gear flank (drive
side) ;
the arc length of the longitudinal line of gear flank (drive s i d e ) ;
of gear flank (drive s i d e ) ;
sez[7]: Lower limit of the pinion root cone beyond the machine centre (drive
side);
sez[8]: Upper limit of the pinion root cone beyond the machine centre (drive
side);
sez[9]-sez[l4]: The corresponding weights of the the parameters, the EVs of
these parameters are expressed by sez [ 1 ]-sez [ 6 ] ( drive
side);
sez[l]: Expected value ( E V ) of geodetic curvature of CPP on gear flank (re-
verse s i d e ) ;
the arc length of CPP on gear flank (reverse s i d e ) ;
(reverse s i d e ) ;
spect to the arc length of the longitudinal line of gear flank (reverse
side) ;
the arc length of the longitudinal line of gear flank (reverse s i d e ) ;
of gear flank (reverse s i d e ) ;
sez[7]: Lower limit of the pinion root cone beyond the machine centre ( r e -
verse s i d e ) ;
sez[8]: Upper limit of the pinion root cone beyond the machine centre ( r e -
verse side) ;
sez[9]-sez[l4]: The corresponding weights of the the parameters, the EVs of
these parameters are expressed by sez [ l ] - s e z [ β ] (reverse
side) ;
4 NUMERICAL EXAMPLE
The input and output parameters of using a generator with modified-roll mechanism
to machine the pinion of a pair of hypoid gears are listed below :
Input parameters:
1 1
0.43868947 26.63177872
35 3.93583417 6.16666667
134.1341627 0 0
152.4 4.046
1.010356061 90
73.71020617 6.08353352
35.09877803 0
9.135772509 20
0
13.6 13.6
25 38
136.7960806 6.468706998
16.8
-0.0004
0
26.633333333 26.633333333
35 42
136.7960806 6.468706998
16.8
0.0004
138.42
0.01 1
0.01 9.738243383
0 0 0 0 0 0
20 50
APPENDICES 237
0.5 0.2 1 0 1 0.1 0.1

0 0 0 0 0 0
20 50
0.5 0.2 1 0.1 0 1 0.1
Because of the limit of the possible width of a page, both the spaces between num-
bers and length of numbers of the output listed below are reduced. Each line of the
second mounting error sensitivity matrix is written in two lines.
1.00000000e+00 4.38689470e-01 2.66317787e+01 3.50000000e+01

3.93583417e+00 6.16666667e+00 1.34134163e+02 0.00000000e+00
0.00000000e+00 1.52400000e+02 4.04600000e+00 1.01035606e+00
9.00000000e+01 7.37102062e+01 6.08353352e+00 3.50987780e+01
0.00000000e+00 9.13577251e+00 2.00000000e+01 0.00000000e+00
1.36000000e+01 1.36000000e+01 2.50000000e+01 3.80000000e+01
1.36796081e+02 6.46870700e+00 1.68000000e+01 -4.00000000e-04
0.00000000e+00 0.00000000e+00 0.00000000e+00
0.00000000e+00 0.00000000e+00 0.00000000e+00
5.00000000e-01 2.00000000e-01 1.00000000e+00
1.00000000e-01 1.00000000e-01 1.00000000e-01
MACHINE SETTING (DRIVE SIDE)

Ep = 3.2600e+01 X = 3.1545e+01 ulf = 6.1061e+00
Cmr =-1.2332e+00 gamaf = 9.1358e+00 Sp = 1.3034e+02
q = 8.9270e+01 Xbp = 5.0086e+00
CUTTER PARAMETERS
Phi = 1.3600e+01 Rp = 1.4958e+02 R = 1.5110e+02
CONTACT PARAMETERS
dsl= 2.217e+01 ds2= 1.052e+01
V(sigma)= 1.587e+01 V(sigma)p= 1.586e+01
11= 1.568e+00 12= 1.766e+01 kapa= 1.792e+01
ddsl= 2.167e+01 dds2= 1.819e+00 Gl = -2.494E-02 G2= 2.128e-03
Ql=-4.077e-02 Q2 = -l.128e-02 dll= 7.972e-02 dl2= 6.889e-03
ddu21=-7.318e-05
dV=-4.206e-02 dH= 6.161e-02
d(nu)/ds*= 1.479e-02 d(u21)/ds*= 1.756e-05
d(kapa)/ds*= 1.392e-3 d(ll)/cs*= 1.006e-02 d(12)/ds*=-9.387e-03
-4.51559e+01 1.11619e+01 8.30433e+00 2.09429e+01
2.08524e+01 3.89160e+00 4.01966e+00 -1.40457e+01
5.78973e+01 1.18344e+01 1.12277e+01 -4.22344e+01
2.61918e+03 1.66785e+02 1.61482e+02 -1.81985e+03
-4.6791e+01 -2.5641e+00 1.3437e+00 3.2851e-01 3.1823e-04
2.9283e+01 1.9254e+00 -5.7890e-01 -2,7766e-01 -1.6276e-04
8.0876e+01 7.2651e+00 -1.2995e+00 -1.6564e-01 -8.9563e-05
3.2176e+03 5.1785e+02 -3.1254e+01 5.6438e+01 3.0775e-02
1.9016e+00 2.5180e-01 -1.7768e+00 -3.2587e-01

-8.9225e-01 -1.4777e-01 1.1092e+00 -1.0037e+00
-2.4859e+00 -4.0546e-01 3.1212e+00 1.9271e-03
-1.1215e+02 -1.8595e+01 1.2960e+02 3.1628e+02
1.00000000e+00 4., 3 8 6 8 9 4 7 0 e - 0 1 2.66317787e+01 3.50000000e+01

3.93583417e+00 6., 1 6 6 6 6 6 6 7 e + 0 0 1.34134163e+02 0.00000000e+00
0.00000000e+00 1,, 5 2 4 0 0 0 0 0 e + 0 2 4.04600000e+00 1.01035606e+00
9.00000000e+01 7,, 3 7 1 0 2 0 6 2 e + 0 1 6.08353352e+00 3.50987780e+01
0.00000000e+00 9.13577251e+00 2.00000000e+01 0.00000000e+00
2.66333333e+01 2.66333333e+01 3.50000000e+01 4.20000000e+01
1.36796081e+02 6.46870700e+00 1.68000000e+01 4.00000000e-04
0.00000000e+00 0.00000000e+00 0.00000000e+00
0.00000000e+00 0.00000000e+00 0.00000000e+00
5.00000000e-01 2.00000000e-01 1.00000000e+00
1.00000000e-01 1.00000000e-01 1.00000000e-01
MACHINE SETTING (REVERSE SIDE)

Ep = 3.8480e+01 X = 2,,6094e+01 ulf = 6.1910e+00
Cmr =-4.5313e-01 gamaf = 9,,1358e+00 Sp = 1.3482e+02
q = 8.0490e+01 Xbp = 4,,1431e+00
CUTTER PARAMETERS
Phi = 2.6633e+01 Rp = 1.5264e+02 R = 1.4903e+02
CONTACT PARAMETERS
dsl = 2.107e+01 ds2= 8.776e+00
V(sigma)= 1.432e+01 V(sigma)p= 1.427e+01
11= 1.429e+00 12= 1.795e+01 kapa= 2.060e+01
ddsl=-1.727e+01 dds2=4.551e+00 Gl= 2.395E-02 G2= 3.144e-03
Ql= 2.140e-02 Q2 = -2.358e-02 dll=-4.445e-02 dl2= 1.006e-03
ddu21=-1.647e-04
dV= 4.989e-02 dH = -7.049e-02
d(nu)/ds*= 1.687e-02 d(u21)/ds*=-l.554e-05
d(kapa)/ds*=-8.190e-4 d(ll)/ds*= 8.455e-03 d(12)/ds*=-3.205e-02
4.84043e+01 -4.89073e+00 6.89867e+00 -2.16354e+01
-2.11145e+01 3.59754e+00 -1.45450e+00 7.92793e+00
-5.25312e+01 -1.84798e+01 -3.00404e+01 3.04624e+01
3.37888e+03 9.19600e+02 1.65712e+03 -1.75057e+03
APPENDICES 239
-4.0976e+01 9.8379e+00 9.5022e-01 ■4.7060e-01 -2.1960e-04

1.7479e+01 -4.2530e+00 -4.7958e-01 3.9086e-02 1.7794e-04
5.7912e+01 -1.7154e+01 -1.1195e+00 2.8309e-01 6.6496e-04
-3.7560e+03 1.2466e+03 1.0361e+02 5.7129e+01 -6.8371e-02
1.0405e+00 -5.0452e-01 -9.4484e-01 3.5665e-02
-4.6036e-01 2.0356e-01 4.0245e-01 -3.1711e-01
-1.0588e+00 6.9273e-01 1.2630e+00 5.1507e-01
6.8795e+01 -4.0878e+01 -7.9291e+01 2.9581e+02
5 U S E R ' S GUIDE FOR APPENDICES 2 AND 3
The programs can run on a desk-top computer in Turbo Pascal enviroment. For run-
ning program CT (for a generator with cutter-tilt m e c h a n i s m ) , a data file named
C T . D A T should be established according to the input data list at the end of Ap-
pendix 2. For running program MR (for a generator with modified-roll machanism) ,
a data file named MR. D A T should be established according to the input data list at
the end of Appendix 3. The data files include five p a r t s : the information of gera
blank, cutter and machine-setting parameters, predetermined second-order contact
situations, data of the generator to be used and data for optimization.
Since the programs are very complicated, numerical processor 8087 cannot be used,
otherwise errors may occur. If the computer has an 8087, the user should key in an
order " S E T 87 = N" before running the program.
If the final step of optimization is chosen to be 0. 0 1 , the step of blank offset will be
0. 01 m m , and the step of the blade angle of the cutter being 1 minute.
If the user wants to use a set of blades right on hand, both the upper and lower li-
mits of the blade angle of the cutter for machining the pinion should be set to be the
value of those blades. T h u s the blade angle of the cutter will be kept unchanged dur-
ing optimizing process, and the program will run more faster. The user can also give
a suitable range of blade angle for optimization and run the program at first, then
choose a set of blades on hand with the blade angle near that suggested by the com-
puter and set the limits according to the s e t , and finally run the program again for
optimizing machine-setting parameters.
If a bevel gear generator with neither cutter-tilt not modified-roll mechanism is used
for machining the pinion flank of a gear pair, program MR should be run at first to
optimize the blade angle of the cutter. Then set both upper and lower limits of the
blade angle in C T . D A T equal to the value, or the value of blades on hand with near
value, set both vertical and horizontal tilt equal to zero, set optimization off ( the
first input data equal to z e r o ) , and run CT. However, a gear pair manufactured in
this way cannot ensure that the contact performance will be good enough, although
the predetermined second-order contact parameters can still be guaranteed.
APPENDICES 241
The user had better write a small program to establish the required data files. T h u s
the programs can be used more conveniently.

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STUDIES IN APPLIED MECHANICS

1. Mechanics and Strength of Materials (Skalmierski)

General Advisory Editor to this Series:

This book is sold in conjuction with a diskette.

ISBN Set: 0-444-81705-0

© 1994 Elsevier Science B.V. All rights reserved.

No responsibility isassumedbythepublisherforany injury and/ordamagetopersonsorproperty

This book is printed on acid-free paper.

Printed in The Netherlands

The importance of gears as the principal mechanisms for transmitting motion in

Professor Wang and Professor Ghosh have combined, in a striking example of

January 1994 Trevor C. Bonner

This book is intended for the postgraduate s t u d e n t s , lecturers, professor, or re-

Xian, P R China, Siegburg, Germany, June 1993

Analysis of Combined Mismatched

An analytical method, without any unreasonable assumption, is presented in this

Fig. 1.1 An illustration of the contact of mismatched surfaces

1. 2 ESTABLISHMENT OF MOVING FRAMES

d r<2) = Ωι~εχ + Ω2ε2

ά ~εχ = Ω\~ε2 + Ω\ε3

dex =dex + α α > X ex d^ x)

de3 = de3 + α α > X β3ά^

d#<2> = d r<2) + ä (2) X Ri2) άφ{2)

From Fig. 1. 1 it is easily seen that

fl<l> = fl<2> + L (1.7)

As we know, the mathematical expression of a surface can be developed into a Tay-

FromEqs . ( 1 . 9 ) · ( 1 . 5 ) , ( 1 . 6 ) , ( 1 . 1 ) and ( 1 . 2 ) we obtain

ω1 *! + S 2~e2+ äa) X Ra) dp(1> = Ω1 ex + Ω2 e2 + ä<2) X £ < 2 ) dp<2) (1.12)

This is the instantaneous transmission ratio. Substituting Eqs. ( 1 . 5 ) , ( 1 . 6 ) » ( 1 . 1 )

- 3» ex - Z\~e2+ äa) X *3 α Υ η = - Ω\ ^ - Ω\ ϊ2 + ä<2> X *3 d^ 2)

^ d f ^ + "<2>'έ* | S = - * i ° d f * c o s * ~ « l > d ^ s i n * + 5<" ·

* ? > [ " d ^ sin ^ + dd<p<^ cos ^ + ο α \* α \έ 2 )] + *ί1} 5 ^ sin ^

bx (k[2) - ^ > ) sin ψ

(£<2) - k[l)) cos ψ bx

bl = [£<2>(^<2>,#<2>,0 + 5<2> · e,] ^ y - kl»ta™9R™9iO - αα> · l2

£2 = [*<2>(α<2\*<2\έ2) - 5<2> . i j ^ - k™&»9R™9iJ + ä(1> · έχ

denotes the relative angular velocity between the gears, and

Fig. 1. 4 The principal directions

£-(21) = *«> c o s 2 ( A _ φ) + *«> sin2(A - 0 ) - ä^cos 2 A - jfe^sin2 A (1. 27)

This imaginary surface is called difference surface at M. The principal directions of

id) _ I t -i - Ri2) sin 2ψ (1.28)

Ra> = tta> _ £<i>)/2, R«> = Cki2> - ^2>)/2 (1.29)

The angle from εχ to ii is

Λ<2> = λ<ι> - ^ (1.30)

As we k n o w , the principal directions of the instantaneous contact spot coincide with

Both the principal relative curvatures can be expressed as

^1 2 l ^2 2 l ^1»1 3 I ^1.2 2 ι ^2,1 9 1 ^2,2 3 1

z = —xz + -y2 + -jhx* + -y*2y + ~Y*y + -j^y + *

dk}» =ki}}% (*,; = 1,2) (1.34)

d # 2 ) = k% & (i, j = 1 , 2 ) ( 1 . 35)

άωι - άω2 - ω1 aex ω2 de2 - ( 1 ) d # (1)

άΩ1 - , d ß 2 - , ß 1 de\ . Ω2 άε2

. A^. + 5a)Xi?Ld^ (I) - d^2>

,1 dS1 S2 _ω|_| . y/ dS2 , 5 1 ω2 | , | - ( 1 ) d ^ - \

_ dß^ _ _ß^_ J3L i5(,> ^ - | d ^ -(2) ^(2) έ dV2>

■ « < . > .e;2 d V 2 > 2

Λ_ - j±_ . -d) - jß|_ _ jßf_ , -(2) - d ^ (1.38)

d^( dk™ ft)1 S2 ft)2 1

d£| 2)Ü Jβ^2 _ ^<2> JL· J L , f-<2> ^ 5 L Ϊ ] d j ^ _ - ( 2 ) . - dy 2 >

Thus the derivatives of ΊΠΤΪ) and ΊΠΤΪ) can be determined b y :

Cx Ofe{2> - kiiy) sin 0

Cl = - 9Ri2) -^— — = ^ - -^— 4- ω<21) >δ(2) —a ) l· -=^_ e

Fig. 1. 6 An illustration of the moving frame before and after

- 3» ex - Z\~e2+ äa) X 3 α Υ η = - Ω\ ^ - Ω\ ϊ2 + ä<2> X 3 d^ 2)

£2 = [<2>(α<2\<2\έ2) - 5<2> . i j ^ - k™&»9R™9iJ + ä(1> · έχ

£-(21) = «> c o s 2 ( A _ φ) + «> sin2(A - 0 ) - ä^cos 2 A - jfe^sin2 A (1. 27)

z = —xz + -y2 + -jhx* + -y2y + ~Yy + -j^y + *

' ^£1 sin2 θ + r</> s i n 2Θ | ^ | (/> - <'> - r<'> sin 20)

+ &> sin (0 + 0 j ) ] T G sin 2 0, - (k[f> - K>) sin 2 0 χ | ^ (2. 30)