A new type of face gear drive for application in transmissions, particularly in helicopters, has been developed. The new geometty differs from the existing geometry by application of asymmetric profiles and double-crowned pinion of the face gear mesh. The paper describes the computerized design, simulation of meshing and contact, and stress analysis by finite element method. Special purpose computer codes have been developed to conduct the analysis. The analysis of this new type of face gear is illustrated with a numerical example.

The use of face gears in power transmission and drive systems has a significant number of benefits. Face gears allow a variety of new transmission arrangements as well as high reduction ratio capability. This leads to drive system weight reduction and improvements in performance. In this work, basic information about the design and analysis of face gear drives is presented. The work considers face gears in mesh with spur involute pinions for both intersecting axes and offset drives. Tooth geometry, kinematics, generation of face gears with localized bearing contact by cutting and grinding, avoidance of tooth undercutting, avoidance of tooth pointing, tooth contact analysis, and algorithms for the simulation of meshing and contact arc all topics which are discussed. In addition, applications of face gear drives are presented. Included are design uses in aerospace applications such as helicopter transmissions, split-torque face gear arrangements, comparisons of face gears with bevel gears, and general design considerations. Litvin, F. L. and Egelja, A. and Tan, J. and Chen, D. Y.-D. and Heath, G. Glenn Research Center NCC3-356; RTOP 581-30-13; DA Proj. 1L1-62211-A4-7A

A face gear drive with a spur involute pinion is considered. The generation of the face gear is based on application of a grinding or cutting worm whereas the conventional method of generation is based on application of an involute shaper. An analytical approach for determination of: (1) the worm thread surface, (2) avoidance of singularities of the worm thread surface, (3) dressing of the worm, and (4) determination of stresses of the face-gear drive, is proposed. A computer program for simulation of meshing and contact of the pinion and face-gear has been developed. Correction of machine-tool settings is proposed for reduction of the shift of the bearing contact caused by misalignment. An automatic development of the model of five contacting teeth has been proposed for stress analysis. Numerical examples for illustration of the developed theory are provided.

A new method for design and generation of spiral bevel gears of uniform tooth depth with localized bearing contact and low level of transmission errors is considered. The main features of the proposed approach are as follows: (1) The localization of the bearing contact is achieved by the mismatch of the generating surfaces. The bearing contact may be provided in the longitudinal direction, or in the direction across the surface; and (2) The low level of transmission errors is achieved due to application of nonlinear relations between the motions of the gear and the gear head-cutter. Such relations may be provided by application of a CNC machine. The generation of the pinion is based on application of linear relations between the motions of the tool and the pinion being generated. The relations described above permit a parabolic function of transmission errors to be obtained that is able to absorb almost linear functions caused by errors of gear alignment. A computer code has been written for the meshing and contact of the spiral bevel gears with the proposed geometry. The effect of misalignment on the proposed geometry has also been determined. Numerical examples for illustration of the proposed theory have been provided. Litvin, F. L. and Zhao, X. Glenn Research Center...

A new type of face-gear drive with intersected axes of rotation formed by a helical involute pinion and conjugated face-gear has been investigated. Generation of face-gears by a shaper free of undercutting and pointing has been investigated. A new method of grinding or cutting of face-gears by a worm of special shape has been developed. A computerized design procedure has been developed to avoid undercutting and pointing by a shaper or by a generating worm. Also, a method to determine the limitations of the helix angle magnitude has been developed. The method provides a localization of the bearing contact to reduce the shift of bearing contact caused by misalignment. The analytical method provides a simulation of the meshing and contact of misaligned gear drives. An automatic mesh generation method has been developed and used to conduct a 3D contact stress analysis of several teeth. The theory developed is illustrated with several examples.Litvin, Faydor L. and Fuentes, Alfonso and Gonzalez-Perez, Ignacio and Piscopo, Alessandro and Ruzziconi, PaoloGlenn Research CenterSHAPERS; GEAR TEETH; TRANSMISSIONS (MACHINE ELEMENTS); STRESS ANALYSIS; SINGULARITY (MATHEMATICS); HELICES; MECHANICAL ENGINEERING; AXES OF ROTATION; COMPUTER SYSTEMS DESIGN; CONJUGATION; MISALIGNMENT; POSITION (LOCATION); MECHANICAL DRIVES; HELICOPTERS; GRID GENERATION (MATHEMATICS)

A procedure was developed to perform tooth contact analysis between a face gear meshing with a spur pinion using finite element analysis. The face gear surface points from a previous analysis were used to create a connected tooth solid model without gaps or overlaps. The face gear surface points were used to create a five tooth face gear Patran model (with rim) using Patran PCL commands. These commands were saved in a series of session files suitable for Patran input. A four tooth spur gear that meshes with the face gear was designed and constructed with Patran PCL commands. These commands were also saved in a session files suitable for Patran input. The orientation of the spur gear required for meshing with the face gear was determined. The required rotations and translations are described and built into the session file for the spur gear. The Abaqus commands for three-dimensional meshing were determined and verified for a simplified model containing one spur tooth and one face gear tooth. The boundary conditions, loads, and weak spring constraints were determined to make the simplified model work. The load steps and load increments to establish contact and obtain a realistic load was determined for the simplified two tooth model. Contact patterns give some insight into required mesh density. Building the two gears in two different local coordinate systems and rotating the local coordinate systems was verified as an easy way to roll the gearset through mesh. Due to limitation of swap space, disk space and time constraints of the summer period, the larger model was not completed.Bibel, George and Lewicki, David G. (Technical Monitor)Glenn Research CenterROTATION; GEAR TEETH; BOUNDARY CONDITIONS; FINITE ELEMENT METHOD; TIME; COMPUTER PROGRAMS; LOADS (FORCES)