Abstract
Tool errors are inevitable in an actual gear-manufacturing environment and may directly affect the accuracy of machined tooth surfaces. In this paper, tool errors including spheric radius, pressure angle, rake angle, regrind angle, and cutting side relief angle errors for three-face blade are defined and considered to establish the accurate tooth surface mathematical model for face-hobbed hypoid gears based on the manufacturing process and the meshing theory. The simulation flowchart for tooth surface modeling and tooth surface topography deviation analysis are proposed and performed. Results show that the tooth surface deviation is positive with positive spheric radius and rake angle errors and contrary results can be found for other three tool errors. In addition, the impact of the pressure angle error is the strongest. In addition, the rake angle error has the weakest effect and the influence of spheric radius error on the tooth surface deviation is unsubstantial. For location of tooth surface deviation, the maximum deviation is at the top on the heel and the minimum deviation is at the middle on the toe for spheric radius error. The maximum and minimum deviations are at the top and the middle tooth on the heel for other factors, respectively.
