Design for manufacturing of a spur gears profile modification based on the static transmission error for improving the dynamic behavior

This study presents a novel iterative algorithm for obtaining an improved profile modification for spur gears based on minimizing the peak-to-peak static transmission error. Two improved profile modifications, obtained with different initial constraints applied to the tooth profile, were calculated and characterized. The static behavior of the gears was analyzed using a finite element model, by which the modifications were compared considering the maximum contact pressure and peak-to-peak static transmission error. The dynamic behavior of the gears was analyzed using a lumped parameter model. The dynamic overload and the dynamic transmission error were evaluated under several working regimes. The grinding wheel profiles used to realize the proposed profile modifications and the total volume of material removed were calculated using a CAD model. The results showed that the proposed modifications lead to a significant improvement in the static and dynamic behavior of the transmission by reducing both the maximum dynamic overload and meshing noise. The profiles of the grinding wheel were found to be accurately represented by polynomial functions, thus a feasible manufacturing process can be obtained. The total volume of material removed was lower than that produced by commonly adopted profile modifications, thus reducing material waste and increasing the productivity of the manufacturing process compared to standard profile modifications.