PSYCHOACOUSTIC GEAR TOOTH FLANK FORM MODIFICATION
A method of producing a tooth flank surface on gear teeth by controlled removal of stock material from a work gear with a tool with the work gear and the tool being movable with respect to one another along and/or about a plurality of axes. The tool and work gear are engaged with one another and then moved relative to one another in a generating motion along and/or about the plurality of axes. Stock material is removed from the work gear to produce the tooth surface on the work gear. The generating motion along and/or about the plurality of axes comprises motion along and/or about at least one of the axes with the motion being defined by a function having a first level component and a second level component. The first level component defining a maximum flank form deviation amplitude for each tooth of the work gear, and the second level component defining a modification of the tooth surface of each tooth of the work gear.
1 . A method of producing a tooth flank surface on gear teeth by controlled removal of stock material from a work gear with a tool, said work gear and said tool being movable with respect to one another along and/or about a plurality of axes, said method comprising:
engaging said tool with said work gear,
moving said tool and said work gear relative to one another in a generating motion along and/or about said plurality of axes,
removing stock material from the work gear to produce the tooth surface on said work gear,
wherein the generating motion along and/or about said plurality of axes comprises motion along and/or about at least one of the axes, said motion being defined by a function comprising a first level component and a second level component, said first level component defining a maximum flank form deviation amplitude for each tooth of the work gear, and said second level component defining a modification of the tooth surface of each tooth of the work gear.
2 . The method of claim 1 wherein the first level component comprises at least one of a cosine function and a normal distribution.
3 . The method of claim 1 wherein the second level component is determined along the path of contact of each tooth of the work gear.
4 . The method of claim 3 wherein determination of the second level component includes tooth to tooth magnitudes obtained from the first level component.
5 . A method of producing a tooth flank surface on gear teeth by controlled removal of stock material from a work gear with a tool, said method comprising:
providing a gear producing machine, said machine having plurality of axes and comprising a work piece spindle rotatable about a work axis A and a tool spindle rotatable about a tool axis C, said work piece spindle and said tool spindle being movable with respect to one another along at least one of linear axes X, Y and Z and about a pivot axis B,
providing a workpiece on said work piece spindle,
providing a tool on said tool spindle,
engaging said tool with said work gear,
moving said tool and said work gear relative to one another in a generating motion comprising a generating roll along and/or about said plurality of axes,
removing stock material from the work gear to produce the tooth surface on said work gear,
wherein the generating motion along and/or about said plurality of axes comprises a modified motion along and/or about at least one of the axes, said modified motion being defined by a function comprising a first level component and a second level component, said first level component defining a maximum flank form deviation amplitude for each tooth of the work gear, and said second level component defining a modification of the tooth surface of each tooth of the work gear.
6 . The method of claim 5 wherein said modified motion comprises motion along and/or about at least one of:
angular motion about workpiece axis A,
linear motion X in the direction of workpiece axis A, and
linear motion Y in a direction parallel to pivot axis B.
7 . The method of claim 6 wherein linear motion Y is in a vertical direction.
8 . The method of claim 5 wherein the first level component comprises at least one of a cosine function and a normal distribution.
9 . The method of claim 5 wherein the second level component is determined along the path of contact of each tooth of the work gear.
10 . The method of claim 9 wherein determination of the second level component includes tooth to tooth magnitudes obtained from the first level component.
11 . The method of claim 10 wherein the tooth to tooth magnitudes are applied to a tooth bound modification function comprising at least one of:
a first order function,
a sinusoidal function, and
a third order function.
12 . The method of claim 5 further comprising introducing a dwell section in the second level function, said dwell section being located at least at a center of roll position of the generating roll, wherein within said dwell section, the second level function has an amplitude of zero.
13 . The method of claim 12 wherein the dwell comprises at least one of a toe dwell section and a heel dwell section, with the toe dwell section being located between the center of roll position and a toe end of a tooth and the heel dwell section being located between the center of roll position and a heel end of the tooth.
14 . The method of claim 13 wherein each of the toe dwell section and the heel dwell section extend between 0° and 4° of the generating roll.
15 . The method of claim 5 wherein said tool comprises a grinding wheel.
16 . The method of claim 5 wherein the first level component comprises a normal distribution and the second level component comprises a sinusoidal function.