A global synthesis approach for optimizing the meshing performance of hypoid gears based on a swarm intelligence algorithm

To control the meshing performance of hypoid gear drive, current local conjugate theory and local synthesis method establish a relationship between the relative motion and local geometrical properties of the mating surfaces at one reference point. Theoretically, both local conjugate theory and local synthesis method cannot ensure the contact performance on the entire tooth surface resulting in uncontrolled contact pattern and undesirable transmission error. A global synthesis approach consisting of a machine-tool settings calculation model, a tooth contact analysis model, a meshing quality assessment function, and a swarm intelligence algorithm are proposed. The direction, area, and shape of the contact pattern and the amplitude of the intersection of two adjacent transmission error curves are taken as the evaluation indexes. Three curvatures of the design pitch cone of the pinion are taken as the control variables. A global selection space is then established within the reasonable range of the curvatures. An improved multiple population genetic algorithm is employed to find the optimal set of the curvatures to achieve the target values of the evaluation indexes. To avoid the edge contact and corner contact condition, a feasible region is defined on tooth surface and the contact patterns on the gear and pinion surfaces are all confined within the area. The optimized contact patterns obtained by the loaded tooth contact analysis method are similar to those obtained by the proposed approach, thus demonstrating the effectiveness of this methodology. The main novelty of this approach is to translate the derivation of the mathematical relation between the curvatures of the mating surfaces and the contact properties to solving a multi-objective optimization problem of the meshing quality indexes by the intelligence algorithm.