.

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1.

I NASA/CR-2000-209909 ARL-CR447
U.S. ARMY

RESEARCH LABORATORY

Handbook on Face Gear Drives With a

Spur Involute Pinion
EL. Litvin and A. Egelja
University of Illinois at Chicago, Chicago, Illinois

J. Tan, D.Y-D. Chen, and G. Heath

The Boeing Company, Mesa, Arizona
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 NASA/CR-2000-209909 ARL-CR447
U.S. ARMY

I ’
RESEARCH LABORATORY

Handbook on Face Gear Drives With a

,

Spur Involute Pinion

EL. Litvin and A. Egelja
University of Illinois at Chicago, Chicago, Illinois

J. Tan, D.Y-D. Chen, and G. Heath

The Boeing Company, Mesa, Arizona

Prepared under Contract NCC3-356

National Aeronautics and

Space Administration

,
Glenn Research Center

March 2000
 Available from

NASA Center for Aerospace Information National Technical Information Service ,

7121 Standard Drive 5285 Port Royal Road
Hanover, MD 21076 Springfield, VA 22100
Price Code: A06 Price Code: A06
 CONTENTS

Introduction

Part 1: Face Gear Drives with Intersected Axes

1.1 General Considerations

1.2 Instantaneous Axis of Rotation, Pitch Cones, Pitch Surfaces

1.3 Generation of Face Gears with Localized Bearing Contact

1.4 Shaper Tooth Surface

1.5 Face Gear Tooth Surface

1.6 Avoidance of Tooth Undercutting

1.7 Avoidance of Tooth Pointing

1.8 Tooth Contact Ellipse

1.9 Algorithms for Simulation of Meshing and Contact

Part 2: Offset Face Gear Drives

2.1 General Considerations

2.2 Axes of Meshing

2.3 Tooth Pointing

2.4 Localization of Bearing Contact and Simulation of Meshing

Part 3: Applications for Face Gear Drives

3.1 Design Uses for Face Gears in Aerospace Applications

3.2 Comparisons of Face Gears with Bevel Gears

3.3 Split Torque Face Gear Arrangements

3.4 Design Considerations for Face Gear Usage

References

Figures

NASA/CR-2000-209909
Introduction

This Handbook is the condensed summary of the results of research that was conducted

at the Gear Research Laboratory of the University of Illinois at Chicago, and the Boeing

Company in Mesa, Arizona. The research was jointly sponsored by DARPA (Defense Ad-

vanced Research Projects Agency) and the Boeing Company Phantom Works, with technical

and administrative support by NASA. The research at the Gear Research Laboratory was

accomplished under the supervision of Professor F. L. Litvin with participation of Dr. A.

Egelja, Dr. C.-L. Hsiao, Dr. J. Lu, Dr. I. Seol., Dr. J.-C. Wang and Dr. Y. Zhang.

The results of the research are included in [7], [8], [9], [lo], and [ll]. Face gear durability

test evaluations relating to the above projects were performed at the NASA John H. Glenn

Research Center. Results of initial and current testing conducted at the NASA GRC are

included in [14] and [15].

Face gear drives were previously a subject of research by Y. S. Davidov [2], Liburkin,

Litvin [5], [7], Crown Gear B.V. Company [I] and others. The contents of the Handbook

cover the latest developments accomplished at the Gear Research Laboratory and represent

the basic information about the design of face gear drives, generation of face gears by cutting

and grinding, computerized simulation of meshing and contact, and the application of face

gear drives in helicopter transmissions. Although there is much more to be learned about

face gear drives, it is felt that they are about to take a prominent place among the gearing

options available to drive systems engineers. The advantages they offer in torque splitting

arrangements, high ratio capability, and strength will provide the motivation to bring this

technology to its full fruition.

NASA/CR-2000-209909
 Part 1
Face Gear Drives with Intersected Axes

1.1 General Considerat ions

A face gear drive used for transformation of rotation and torque between intersected

axes (fig. 1.1.1) is an alternative one for a spiral bevel gear drive. The driving member

of a face gear drive is an involute spur pinion. The bearing contact in a face gear drive is

localized (see section 1.3) to avoid the separation of tooth surfaces and edge contact due to

misalignment.

The advantages of a face gear drive are:

(1) The possibility to split the torque in a gear transmission, particularly in a helicopter

transmission as shown in figs. 1.1.2(b) and 1.1.3. Application of spiral bevel gears for this

purpose is less favorable (fig. 1.1.2(a)).

(2) More favorable conditions of transfer of meshing when one pair of teeth is changed for

the neighboring one. Due to misalignment, the transfer of meshing in other types of gear

drives is accompanied by transmission errors that cause vibration and noise. The advantage

of face gear drives is that misalignment does not cause transmission errors at the transfer

of meshing, because the involute pinion tooth surfaces are equidistant. However, errors of

alignment in a face gear drive may cause a shift in the bearing contact, therefore localization

and stabilization of the bearing contact become necessary (see section 1.3).

The design of face gear drives requires the observation of the following conditions:

(1) Avoidance of undercutting and pointing of the face gear teeth.

(2) Favorable relation between the tooth length ’ 1 ’ and the diametral pitch Pd.

NASA/CR-2000-209909 4
 The structure of a tooth of a face gear generated by a shaper is shown in fig. 1.1.4. The

tooth surface is covered by lines Lzs, lines of tangency of the face gear 2 with the shaper s.

The fillet of the tooth surface of the face gear is generated by the edge of the shaper tooth,

and L* is the line of tangency of both parts of the tooth surface. Undercutting may occur

in a cross-section A, and pointing in a cross-section B. Fig. 1.1.5 shows the schematic of a

face gear of a non-orthogonal gear drive. The intersected axes of the pinion (or shaper) and

the face gear form an angle 3;n that differs from 90”. Dimensions Rr and RZ determine the

locations of cross-sections A and II. The tooth length 1 is determined as:

I= R2 - RI (1)
A unitless coefficient c is represented as

c = 1Pd (2)

The strength of the teeth depends on c. To obtain c > 10, it is recommended to choose the

following values:

NV 2
m12=- >5 ) NI 2 a, = 25” (3)
Nl l-COSCX, ’

where Nr and N2 are the numbers of teeth in the pinion and the gear, QI, is the nominal

pressure angle, and ml2 is the gear ratio.

1.2 Instantaneous Axis of Rotation, Pitch Cones, Pitch Surfaces

Instantaneous Axis of Rot at ion

Fig 1.2.1 (a ) shows that rotation with angular velocities w(‘)and ,(‘) is performed between

intersected axes 01 and 02 that form an angle y. There is such an axis 01 that lies in the

plane formed by axes of rotation 01 and 02 that is defined as follows:

(i) At any point M of 01 the following vector equation is observed

w(l) x p, = d2) x p, (4)

NASA/CR-2000-209909 5
Here: pi (i = 1,2) is the position vector of point M.

(ii) Equation (4) means that

,jl, = v12’l
(5)

where vci) is the linear velocity of point M in rotation about axis Oi (i = 1,2).

(iii) Equation (5) yields that

&2) = +l) _ g21 = ()
(6)

This means that the relative linear velocity at a point of the instantaneous axis of rotation

01 is equal to zero.

(iv) The instantaneous axis of rotation 01 forms angles y1 and y2 with axes of rotation 01

and 02, respectively (fig. 1.2.1(a)). Here:

ml? + cos y
cot y1 = (7)
sin y

rng + cos y
cot 7‘ = = 1+ m1l,cosy (8)
sin y mli, sin y

where
N‘ sin y1 rnzl = -
1
m12.= - = -
Nl sin yL’ ’ ml2
(9)

Pitch Cones

We may consider two cones with apex angles y1 and y2 that are rotated about axes 01

and 02 with angular velocities ,(‘j and w(‘j. The relative motion of one cone with respect

to the other one is rolling without sliding. This rolling is rotation about the instantaneous

axis of rotation with angular velocity:

(9 w (12) = w(l) _ wP:j

when cone 2 is at rest and cone 1 rolls over cone 2;

(ii) wC21) = ~(2) _ w(l) = -w(l”)

when cone 1 is at rest and cone 2 rolls over cone 1.

NASA/CR-2000-209909 6
 The line of action of angular velocities L@) and L#) coincides with the instantaneous

axis of rotation 01. In the case of bevel gears cones 1 and 2 (fig. 1.2.1 (a)) are the pitch

cones, and they are the basis for determination of the addendum and dedendum cones of

the bevel gears.

Pitch Surfaces in a Face Gear Drive

In the case of a face gear drive, the tooth element proportions are determined by appli-

cation of so called pitch surfaces that differ from the pitch cones. The pitch surfaces (fig.

1.2.1(b)) represent a pitch cylinder rP for the shaper (pinion) and a cone of the apex angle

y for the face gear. Angle y is equal to the angle formed by the axes of the shaper (pinion)

and the face gear. The line of tangency of the pitch surfaces O’Q does not coincide with

the instantaneous axis of rotation 01, but intersects it at point P as shown in fig. 1.2.1(b).

The pitch surfaces roll over each other only at point P, but roll and slide at any other point

of O’Q. Radius rP1 is the radius of the shaper (pinion) pitch cylinder for a standard shaper

(pinion), and is the radius of the operating pitch cylinder of the nonstandard shaper (pinion).

Fig. 1.2.2 shows the shaper (pinion) and face gear of a face gear drive with intersected axes.

The teeth have a constant height.

The concept of instantaneous axis of rotation in a face gear drive is applied for approxi-

mate determination of conditions of pointing (see section 1.7).

1.3 Generation of Face Gears with Localized Bearing Contact

The face gear may be generated by shaping, hobbing, or grinding.

Shaping

The generation is based on simulation of meshing of a shaper and the face gear being

generated (fig. 1.3.1). Two approaches for the localization of the bearing contact may be

applied.

NASA/CR-2000-209909
Approach I is based on simulation of meshing by application of a shaper with increased tooth

number N,

N,=Nr+1-3 (10)

where Nr is the pinion tooth number.

We may imagine that the applied shaper and the pinion of the drive are in internal

tangency as shown in fig. 1.3.2. The shortest distance B between the axes of the shaper and

the pinion is represented as

Ns - Nl
B = TP,$ - 7-g = (11)
2pd

During the process of generation, the shaper and the gear perform rotation between inter-

sected axes with angular velocities W’“)and &! related as follows

The axes of rotation of the shaper and the face gear form an angle “em = (180” - 7) (fig.

1.3.1), where y is an angle formed by the axes of the pinion and the face gear (fig. 1.2.2).

The shaper performs a reciprocating motion in the direction of generatrix of the face gear

that is parallel to the shaper axis. The tooth surfaces of the shaper and the face gear are in

line contact at every instant. Lines Lsz (fig. 1.3.3(a)) are the instantaneous lines of tangency

of surfaces C, and C?. the surfaces of the shaper and the face gear.

The shaper tooth surface C, and the pinion tooth surface are also in line contact at every

instant. Lines Lsl are the instantaneous lines of tangency of surfaces C, and Cr (fig. 1.3.3(b)).

The face gear tooth surface CL! and the pinion tootih surface Cr are at every instant in

tangency at a point (designated as h/i in fig. 1.3.3(c)) th at is the point of intersection of

lines of tangency Ls? and Lsl.

The approach discussed above allows the bearing contact to be localized as shown in fig.

1.3.4. The bearing contact is formed as a set of instantaneous contact ellipses. The contact

of surfaces at a point is spread over an ellipse due to the elastic deformation of tooth surfaces.

NASA/CR-2000-209909 8
I I
More details about the determination of the contact ellipses on the gear tooth surface are

given in section 1.8.

Approach 2 is based on the following ideas [9], [12].

(i) The number of teeth of the shaper is the same as the one of the pinion.

(ii) The point contact of the surfaces of the pinion and the face gear is achieved by the

modification of the pinion tooth surface. Such a modification is obtained by a varied plunge

of the tool that generates the pinion.

Figs. 1.3.5 and 1.3.6 show how the varied plunge of the tool is accomplished by form-

grinding (cutting) of the pinion. The axial section of the tool coincides with the involute

profile of the pinion. The tool surface is a surface of revolution. During the pinion generation,

the tool performs two translational motions (figs. 1.3.5 and 1.3.6): (1) in the direction of the

pinion axis, and (2) in the direction of the shortest distance.

Coordinate systems S1 and Sd, shown in the fig. 1.3.6, are rigidly connected to the pinion

and the generating tool. The instantaneous shortest distance E is executed as (fig. 1.3.6)

E = E, - a& (13)
where E, is the nominal value of the shortest distance, Zd is the displacement along the teeth,

ad is the parabola coefficient of the varied plunge

E - E, = a& (14)

The face gear tooth surface & is generated as the envelope to the family of shaper tooth

surfaces C,. Surface C, coincides with the theoretical, unmodified pinion tooth surface &.

Surfaces X2 and C, are in line contact, but surfaces C2 and C1 are in point contact because

Cr is generated by plunging of the tool.

The modified pinion tooth surface may be generated as well by a hob or a grinding worm

that is plunged during the process of generation, similarly to plunging of the form-grinding

tool (fig. 1.3.5 and 1.3.6).

NASA/CR-2000-209909 9
 The advantages of Approach 2 for the localization of the bearing contact are as follows:

(i) The possibility to obtain larger dimensions of the contact ellipse since N, = Ni.

(ii) The possibility to compensate the shift of the bearing contact caused by misalignment

by an axial displacement of the pinion provided with the modified tooth surface with respect

to the face gear.

Hobbing and Grinding

A hob for generating face gears was proposed by E. Miller in patent 2,304,586 (December

8, 1942), titled: Hob for Generating Crown Gears (fig. 1.3.7). The main idea of the patent

is that the surface of the hob thread can be determined as that generated by the involute

profiles of the cross-section of the shaper (fig. 1.3.7). Although the proposed idea of an

application of a hob for generation of crown (face) gears was an innovative one, it was not

supported with sufficiently detailed investigation of the following topics:

(i) The determination of the exact thread surface of the hob and the determination of

deviations of the real surface from the exact one. It should be pointed out that Miller’s

patent proposed to generate the hob by tooth profiles but not tooth surfaces.

(ii) A method for dressing and manufacturing the hob thread surface.

This was the reason why new ideas that cover grinding and hobbing of face gears were

developed. The proposed ideas are as follows:

(1) The shape of the grinding worm (hob) is as shown in fig. 1.3.8.

(2) The worm thread surface can be determined by two alternative approaches:

Approach 1 for Determination of Worm Thread Surface

The worm thread surface C, is the one parameter envelope to the family of the shaper

tooth surfaces C,. Surfaces C, and C, are in line contact at every instant. The worm and

the shaper perform rotation about crossed axes that form angle X,. with angular velocities

NASA/CR-20-209909 10
related as
%
-=-NS
(15)
us Nw
A single thread worm is applied and NW = 1. The angle X, is determined by the relation

sin X, = -TPS
(16)
Nrpw

where rps and rW, are the radii of the pitch cylinders of the shaper and the worm at the

mean contact point.

The dressing of the worm is based on simulation of meshing of the worm with an imaginary

spur pinion that is identical to the shaper. Fig. 1.3.9 shows a segment of the imaginary

spur pinion. The imaginary spur pinion and the shaper complement each other as molding

and casting. Contact lines between surfaces C, and C, are shown in fig. 1.3.10. There is

a possibility of undercutting of the worm thread surface C, by surface C,. Therefore, the

angle of rotation of the worm & being in mesh with the dressing tool must be limited. Due

to asymmetrical location of contact lines and the limiting line on surface II,, each side of

the worm thread surface C, must be ground separately. Due to the low magnitude of the

relative velocity in the process of meshing of the worm and the dressing tool, it is difficult

to obtain a high quality of the worm thread surface.

Approach 2 for Determination of Worm Thread Surface

This approach was developed by Litvin and Seol and is based on the determination of the

worm thread surface C, as the two parameter enveloping of the family of tooth surfaces CL.

Surfaces C, and C2 are in point contact at every instant. The two independent parameters

of motion are: (i) the angle of rotation of the face gear 42 being in mesh with the worm,

and (ii) the translational motion s along the teeth of the face gear. Parameters $2 and s

are considered as independent although they are related in the real process of generation.

However, the relation between & and s does not cause substantial deviations of surface C,

from the theoretical one. The angle of rotation of the worm &, is related with 42 by the

NASA/CR-2000-209909 11
equation

assuming that a one-thread worm is applied.

Dressing of the Worm

A great advantage of the proposed method of dressing is that it is based on application of

a dressing disk that is in point contact with the worm thread surface. The grinding disk and

the worm thread surface are in point contact at every instant. The mathematically defined

worm thread surface C, is generated point by point by the grinding disk. A CNC machine

with five degrees of freedom for the continuous installment and tangency of the disk surface

relative to the worm thread surface is required. A point of the grinding disk as the candidate

point of the tangency must be chosen. The ability to grind the worm thread surface with a

plane (applying for this purpose the plane of a disk) is based on the fact that any point of

the worm thread surface is an elliptical one. We remind the reader that at various elliptical

points of a surface the Gaussian curvature (the product of principal curvatures) is of the

same sign.

Generation of the Face Gear Tooth Surface by a Grinding (Cutting) Worm

Once the worm thread surface C,, has been created, the generation of the face gear tooth

surface can be performed. The generation of the face gear tooth surface X2 by C,, is similar

to the grinding (cutting) of a spur gear by a worm. The worm and the face gear perform

related rotations about crossed axes, the axes of the worm and the face gear. The angles of

rotation #U, and rjz are related by equation (17), assuming that a one-thread worm is applied

and that N, = 1.

Surfaces & and C, are in point contact and therefore the feed motion of the worm,

translation along the direction of face gear teeth must be provided.

NASA/CR-2000-209909 12
1.4 Shaper Tooth Surface

The shaper tooth surfaces are represented in coordinate system S, (fig. 1.4.1). Plane

x, is the plane of symmetry of the space of the shaper. The variable parameters 01;, (k =

,B, 7) and u, are the surface parameters. Parameter u, is measured in the direction of xs.

Parameters Ok8 for the left and the right side profiles are measured in the directions shown

in fig. 1.4.1. The constant parameter O,, determines the half of the space width on the base
-
cylinder. It is measured as shown in fig. 1.4.1 and is determined for a standard shaper by

the equation

oos = z - inva, (18)

2Ns

Here: N, is the number of teeth of the shaper, and ~11, is the pressure angle.

The tooth surface and the surface unit normal are represented by the following equations

hrb, [Wok, + o,,> - oks cos(ok, + &J

r&s, 0,s) = -~bs[cos(~ks + &> + ok, sin(ok;, + &J] (19)

us A

- COS(Oks + ~os>]
7 sin(Ok,, + O,,)]
0

The upper and the lower signs in the equations (19) and (20) correspond to the left and

right side profiles, respectively; rbs is the radius of the base circle.

1.5 Face Gear Tooth Surface

Applied Coordinate Systems

We use the following coordinate systems for derivation of & (fig. 1.5.1): S,(x,, ys, z,) and

S2(~2,y2,~2) th at are rigidly connected to the shaper and the face gear; coordinate systems
.

NASA/CR-2ooO-209909 13
S,, and SP that are rigidly connected to the frame of the cutting machine. Coordinate

systems S, is used for simplification of derivations of coordinate transformation. Angle x,?

is the angle between the pinion shaft rotational axis and the face gear shaft rotational axis.

It is formed between axes x,, and ,zL’ and is determined as yTT2 = (180” - 7) (see designation

in figs. 1.5.1 (a), (b) ).

Equations of the face gear tooth surfaces are represented as follows [7]

M~&$,) r&, h,) (21)

- u,m, sin?,, cos(qh + 8,,s + Ok,) = 0 (22)

where (22) is the equation of meshing.

Matrix Mx, = M~pMp,,M,, is represented by the following equation

cm $2 cos qL+ - cos q$ sin $s

- sin ynl sin & 0
Cos 3/n) sin & sin & + Cos ym sin +J cos &

- sin & cos $s sin & sin $s +

- sin 3/n) cos & 0
ML,, = + Cos 3/nl cos qb2 sin $s cm -ynl cos $2 cos (bs (23)

where
I sin Tnynl sin $s

0
sin ym cos 4s

0
cos Yn,

0
0

1 J

$2 = 4.2 (24)
Vector equation rs ( u,, ok,) is represented by equation (19).

Equations (21) and (22) represent the tooth surfaces of the face gear using three related

parameters. Since parameter u, is a linear one, it can be easily eliminated, and then the

tooth surface of the face gear can be defined by two independent parameters as rz(81;,, &).

NASA/CR-2000-209909 14
1.6 Avoidance of Undercutting

General Approach.

Avoidance of undercutting of face gear teeth can be achieved by the elimination of singular

points of the face gear tooth surface. We remind the reader that at a surface singular point,

the surface normal becomes equal to zero [6], [7]. It was proposed and proven in the works

[6] and [7], that singular points on the generated surface C2 appear if the following vector

equation is observed
&(S) + v(4 = 0
(25)

Here: v~(‘) is the velocity of the contact point on generating surface C,; vcs2) is the relative

velocity of the point of tangency of surface C, with respect to the face gear tooth surface

c-‘.

The differentiated equation of meshing

? f dus ? f d&s
- - - - +af%=O
&L, dt + d&, d t @s dt
(26)

and vectors equation (25) represent a system of four linear equations in terms of two un-
d&s
knowns: $ and z has a certain solution for the

unknowns if the matrix

has the rank T = 2.

This yields that four determinants of the third order are equal to zero. The investigation

shows that the equality of two of them to zero is equivalent to the existence of the equation

of meshing given by equation (22). Therefore, it is necessary to use one of the following two

equations

NASA/CR-2000-209909 15
 A, = (28)

A, = = 0 (29)

Here fiLB, foks, and f*, are the partial derivatives of the equation of meshing taken with

respect to us, Oks, and q$s, respectively. x,, ys, and z, are the coordinates of a point of the

shaper surface C, in coordinate system S,; (v&“‘, v”,?‘, v:“,“) are the components of the

relative velocity in the same coordinate system.

Any of the couple of equations (28) and (29) can be used, and (for example) equation

(28) yields the following relation

Equation (30) with the equation of meshing (22) and the equations of shaper surface

(19) considered simultaneously enable to determine the limiting line L, on the shaper tooth

surface C, (fig. 1.6.1) that will be used for the determination of dimensions of the face gear

free of undercutting. Line L, contains regular points of surface C,, but generates singular

points on surface Cz. Fig. 1.6.2 shows line of singular points on the face gear tooth surface,

generated by line L,. Dashed portion of the face gear tooth surface must be eliminated in

order to avoid undercutting (fig. 1.6.2). In the case of a face gear drive with intersected axes,

due to the symmetry of two sides of face gear tooth surfaces, it is sufficient to determine a

limiting line L, for one of two sides of the shaper tooth surfaces.

NASA/CR-2000-209909 16
 The point of intersection (T) of line L, (fig. 1.6.1) with the addendum cylinder of the

shaper is a critical point of undercutting. The shaper parameter Qks that corresponds to the

addendum of the shaper is determined by equation

** J2zi
ks (31)
rbs

where r,, and rbS are the radii of the addendum and the base cylinder of the shaper. The

coordinates (x:, yg, 2:) of point of intersection of the limiting line L, with the addendum

cylinder of the shaper can be determined by using equation (31) and vector equation (19)

of the shaper surface. The limiting inner radius of the orthogonal face gear Rr (fig. 1.1.5) is

determined as

RI=dm (32)

and the limiting value of the shaper (fig.1.2.2) as

L1 = xs* (33)

where x2 and ~2 are the coordinates of the point on the face gear tooth surface obtained

from coordinates (x,*, & , z,*) by coordinate transformation from S, to &.

If the conditions of non-undercutting are observed, then the fillet surface and the working

surface of the face gear are in tangency and their line of tangency is designated by L* (fig.

1.1.4).

Numerical example: The input data is represented in Table 1

Table 1

INPUT DATA 1
Number of teeth of the shaper N, = 20

Number of teeth of the face gear N2 = 100

Pressure angle a!, = 25”

Diametral pitch Pd = 10 (l/in)

Center distance E = 0 (in)

Intersecting angle +ym = 90

NASA/CR--2ooO-209909 17
Using the input data above, the following auxiliary data is obtained:

- Gear ratio m2s = 0.2

- Radius of the pitch circle of the shaper rps = 1 (in)

- Radius of the base circle of the shaper r6s = 0.9063 (in)

- Radius of the addendum circle of the shaper r,, = 1.125 (in)

- Surface parameter of the shaper addendum 19:~ = 0.735408 (rud) (see equation (31))

Procedure of Computations:

Step I: We use equation of meshing (22), equation (30) and consider as known Q,. Then,

we obtain 4: = - 0.65266(rad) and u,* = 4.57089 (in).

Step 2: We use equations (19) and consider as known 0:, and u,* obtained above. Then, we

obtain the coordinates Z: = -0.16798 (in) and YB = -1.11238 (in) for the critical point 2’

of the shaper Z: = u,*.

Step 3: Using equation (33)) we obtain the limiting length of the shaper surface Lr = 4.57089

(in).

Step 4: Using matrix equation (21) and considering as known uz, 0;, and &, we obtain the

following coordinates of the critical point on the face gear tooth surface Z; = -0.05747 (in),

y; = -4.60257 (in), z; = -0.98577 (in).

Then, using equation (32) we obtain the limiting inner radius of the face gear RI = 4.60292

(in).

1.7 Pointing

Pointing is another negative phenomenon that occurs in the process of generation of the

face gear tooth. The top-land of a face gear tooth is not a constant width (fig. 1.1.4). There

is an area where width of the top-land becomes equal to zero, which means that the tooth

NASA/CR-2000-209909 18
 is pointed. It will cause the weakness of the tooth in that area. One of the design goals is to

properly determine the area of pointing and the outer radius Rz of the face gear blank that

will be free of pointing.

Two approaches are proposed for determination of the area of pointing. The first one

requires simultaneous consideration of the equations of surfaces of both sides of the face

gear tooth and the determination of the area where these two surfaces intersect each other.

. This approach is discussed in Part 2 of this book. The other one is based on application of

the instantaneous axis of rotation and consideration of cross-sections of tooth profiles of the

shaper and the face gear [7] and [9]. Both approaches have been applied using the numerical

examples, and found to have almost identical results.

Approach 2

It was mentioned earlier that this approach is based on consideration of the cross-sections

of tooth surfaces of the shaper and the face gear. Although this alternative approach is only

approximate, it does provide results that are very close to the exact ones. In the case of face

gear drives with intersected axes, the instantaneous axis of rotation is used for determination

of pointing, while in the case of the offset face gear drives the axis of meshing is used instead.

This approach is based on the following considerations:

The face gear is generated by a shaper. The axes of rotation of the shaper and the face

gear are intersected and they are designated by ,zm and x2, respectively (fig. 1.5.1). The

instantaneous axis of rotation is designated by IAs2 and the pitch line by O’P* (fig. 1.7.1).

Point P is the pitch point and point 1 is the current point of the instantaneous axis of

rotation.

Fig. 1.4.1 show that x, = 0 is the plane of symmetry of the shaper space. Any cross-

sections of the shaper tooth surface by planes that are parallel to x, and perpendicular to

z, axis represent the same involute curves. Two such planes, II, and IIp, are shown in fig.

1.7.1. Plane II, intersects the instantaneous axis of rotation IA,2 at a point P that belongs

NASA/CR-2000-209909 19
to the axis of symmetry of the cross-section of the space of the shaper. Similarly, plane II?

intersects the instantaneous axis of rotation IAs2 at a point I. Figs. 1.7.2 and 1.7.3 show

points P and I that are the points of intersection of the instantaneous axis of rotation IAs2

with ITi and II?, respectively. A normal to the shaper tooth surface is perpendicular to z,,-

axis and therefore it lies in plane II, The common normal to the surfaces of the shaper and

the face gear passes through the points P in plane l-III1 and I in plane IIZ. The common

tangents to the cross-section profiles form an angle o, and o, respectively (fig. 1.7.2 and

1.7.3).

Now, assume that plane II, is the plane where the pointing of the cross-section profiles of

the face gear occurs. The investigation shows that in the area where pointing is observed, the

cross-section profiles of the face gear deviate from the straight lines only slightly. Therefore,

it can be assumed that the point K of intersection of the tangents to the profiles (fig. 1.7.3),

is actually the point of intersection of the real cross-section profiles of the face gear.

The consideration discussed above enables us to derive the equations for determination

of the outer radius R2 of the face gear for the zone of pointing using the following procedure.

Step 1: Vector equation (fig. 1.7.3)

~---
O,N+NM+MK=O,K (34)
yields that:
zpdrrn,$
a-tana- = I9 OS (35)
NS
1
where 8,, is represented by the equation (18) and r,, = rPs - -.
pd

Step 2 It is considered that point P belongs to the pitch cylinder of the shaper , and the
location of I with respect to P is determined with segments AZ and Aq (fig. 1.7.1). Drawings

of figs. 1.7.1, 1.7.2 and 1.7.3 yield

N, cos a, - cos a
Aq=O,I-o,P=T”“--
rbs
=-
( > (36)
c o s cy cos& 2Pd cos a

NASA/CR-2000-209909 20
 Aq
Al = - (37)
tan ys
Step 3: The location of plane II2 is determined with parameter R2 in coordinate system

S2 (fig. 1.7.1). Here

(38)

sin y
tarry, = (39)
ms2 + cos y
where y is the crossing angle and ms2 is the gear ratio.

Numerical example: The following numerical example illustrates the above approach for

the avoidance of pointing. The input data are given in the following table.

Table 2

I INPUT DATA 1
Number of teeth of the shaper N, = 20

Number of teeth of the face gear N2 = 100

Pressure angle a:, = 25”

Diametral pitch Pd = 10 (l/in)

Center distance E = 0 (in)

Intersecting angle I “lm = 90” _I

Using the input data above, the following auxiliary data is obtained:

- Gear ratio ms2 = 5

- Radius of the pitch circle of the shaper rpS = 1.0 (in)

- Angle 3/s = 0.197395 (rad) (see equation (39))

- Radius of the shaper r,, = rps - $ = 0.9000 (in)

- Radius of the base circle of the shaper rbS = 0.9063 (in)

Since r,, < rbs it must be taken for the further calculation that r,, = rbs = 0.9063 (in)

NASA/CR-2000-209909 21
 - Half of the space width on the shaper base cylinder is determined with8,,$ = O.O4856(rad)

(see equation (18))

Procedure of Computations Applying Approach 2:

Step 1: We use equation (35), and consider as known: Pd, N, (from the input data) and r,,,s,

80s (from the auxiliary data). Then, we solve equation (35) by using subroutine for solution

of nonlinear equations, and we obtain angle Q = 0.66791 (rud) (fig. 1.7.3).

Step 2: We use equations (36) and (37), and consider as known o, (from the input data),

and CI: obtained in Step 1. Then, we obtain the values Aq = 0.15436 (in) and Al = 0.77184

(in) (fig. 1.7.1).

Step 3: Using equation (38) and considering as known: “/s (from the auxiliary data), N, and

Pd (from the input data), and Aq from Step 2, we obtain the limiting outer radius of the

face gear Rz = 5.7718 (in) (fig. 1.7.1)

1.8 Contact Ellipse

The pinion and the face gear tooth surfaces are in point contact at every instant. Due

to elasticity of tooth surfaces, the contact is spread over an elliptical area. The center of

symmetry of the instantaneous contact ellipse coincides with the theoretical point of tangency

(fig. 1.3.4). The goal is to determine the orientation and dimensions of the contact ellipse

in the tangent plane to the contacting surfaces. This can be accomplished considering as

known: the principal curvatures of two contacting surfaces, the angle g between the unit

vectors ej’) and ej’) which are the principal directions of the surfaces (fig. 1.8.1), and the

elastic deformation 6 of the surfaces at the point of tangency. Note that the ratio between

the major and minor axes of the contact ellipse does not depend on the elastic deformation

6. The elastic deformation depends on the load and it is considered as known from the

experimental data.

NASA/CR-2000-209909 22
 It is easy to determine directly the principal curvatures and the directions for the spur

involute pinion surface. In the case of non-modified spur involute pinion (see Approach 1 for

localization of bearing contact), the curvatures are given by

where Or is the pinion surface parameter and rb, is the radius of the base circle of the pinion.

In the case when the pinion surface is modified (see Approach 2 for localization of bearing

contact) the expressions for the pinion curvatures are more complex.

The problem of determination of principal curvatures and the directions of the face gear

tooth surface requires more complex derivations. A simplified approach to the solution of

this problem is based on direct relations between the principal curvatures of the shaper-tooth

surface and the generated face gear surface [7] (the determination of the principle curvatures

of a face gear tooth surface is performed numerically and requires an algorithm given in [7]).

The principal curvatures of the spur involute shaper are given by

KI0) - _ - 1 -
(41)
(1) = 0
K’II

where 13~ is a shaper surface parameter and rb, is the radius of the base circle of the shaper.

Note that rb, and rb, are different because the number of teeth of the shaper and the pinion

are not the same (see Approach 1 for localization of bearing contact).

The determination of the instantaneous contact ellipse is based on the following equations:

(42)

91 - Q? cos 2cr
cos 2cP) =
(9: - 29192 cm 2a + 9;)

NASA/CR-2OCO209909 23
 ~2 sin 20
sin 2~~“’ =: (45)
(g’I) - 29192 cos 20 + 9;)

l/2 l/2

where
2,=2;
II 7 2b=2i
I I
(46)

- lip - J(g: - 29192 cos 2cr + gii)

I

B = ; @ - /g) + (gf - 29192 cos 2a + 9;)

1 (48)
Here (fig. 1.8.1) a@) is the angle that is formed by axis 77 of the contact ellipse with the

unit vector ej’) of the principal directions on surface Cl; u is the angle formed by unit vectors

e,0)a n d ey) of the principal directions of the contacting surfaces; 2u and 2b are the axes of

the contact ellipse; 6 is the elastic deformation; KY’ and K?] are two principal curvatures of

the tooth surface i.

1.9 Algorithms for Simulation of Meshing and Contact

Simulation of meshing and contact is a significant test of the technology and quality of

the gears. The computer programs that are developed for simulation of meshing and contact

are named TCA (tooth contact analysis). The main idea of TCA is based on simulation of

continuous tangency of tooth surfaces being in mesh.

Assuming that the surfaces are in point contact, TCA is directed at the determination

Of:

(i) transmission errors (caused by errors of assembly)

(ii) the path of contact (its shape and stability)

(iii) the bearing contact as the set of instantaneous contact ellipses

NASA/CR-2000-209909 24
It is assumed that the equations of the gear tooth surfaces are known and that the location

and orientation of gear axes are given. To simulate the errors of assembly (misalignment),

the location and orientation of gear axes of rotation ( shown in figs. 1.9.1 (a), (b), (c) and (d))

differ from the ones designated for gear generation. These errors of assembly are represented

by AE (change of center distance between gear and the pinion axes), Ay (change of crossing

angle), and Aq (the axial displacement of the face gear).

For TCA the following algorithm is applied. -

Assume that three coordinate systems Si$ ,572, and S,f are rigidly connected to the pinion, the

face gear and the frame, respectively.

Step 1: We represent in Sr and ST the tooth surfaces of the pinion and the face gear and the
surface unit normals by the following vector functions

(ui, 0,) E E, (i = 1,2)

(49)

Note: The unit normal to the pinion tooth surface is represented by vector function nl(&).

Step 2: Consider that the pinion tooth surface Ci is rotated about the fixed axis ,zf (fig.

1.9.1(a)). Thus, the pinion tooth surface is represented in S,f by

and its unit normal by

The face gear tooth surface is rotated about another fixed axis z, (fig. 1.9.1 (d)). The

location and orientation of coordinate systems S,, Sd, and S4 with respect to S, enables

us to simulate the errors of alignment. Note that all errors of assembly (misalignment) are

NASAICR-2000-209909 25
referred to the face gear. Finally, we may represent in S, gear tooth surface C2 and the

surface unit normal as

and

ny‘l($,, es, #(J = Lfm(&, &J (53)

Matrices Lij are the 3 x 3 transformation matrices, obtained by elimination of the last row

and column in 4 x 4 homogeneous transformation matrix M,j.

Step 3: The continuous tangency of tooth surfaces is represented by the following conditions
(fig. 1.9.2)

$)(d4,$;) = rj,2’(4s,&&~) (54

nlf’)(Ql. 4;) = nff’(h, es, 4;) (55)

where 4; and 4; are the angles of rotation of the pinion and the face gear being in mesh;

ul, &are pinion surface parameters and c$~, 8, are the face gear surface parameters. Note

that 4; and 4; are different from the angles of rotation $s and $2 that were considered in

meshing of the shaper and the face gear.

Vector equation (54) yields three independent scalar equations, but equation (55) yields

only two independent scalar equations because

(56)
Therefore, vector equations (54) and (55) yield the following system of only five independent

equations

fi(u1,81,~)1,~,,e,,d~) = 0 (i = 1, ..,5) (57)

It is assumed that

(58)
NASA/CR-2000-209909 26
Step 4: The pinion - gear tooth surfaces are in point contact at every instant since the

contact has been localized. Let us assume that the system of equations (57) is satisfied at

point iV&, by the set of parameters

(59)
Since we have 5 equations in 6 unknoxxms, in order to solve this system, we choose one of the

parameters, say &, as the input one.

The system of nonlinear equations (57) may be solved in the neighborhood of P” if the

following inequality is satisfied [7].

A- = Wl, f2, f3> f4? f5> + 0

(60)
3 ~(%,~l,~;,~s,~s)

The solution of equations (57) is obtained by the following functions

(61)
The solution of the system of equations (57) is a continuous iterative process.

(More details about the application of TCA for the case when the localization of bearing

contact is achieved due to different numbers of teeth of the shaper and the pinion are given

in the book “Gear Geometry and Applied Theory” by F. L. Litvin; section 17.11 [7])

The results of computation for simulation of the bearing contact and the paths of contact

are illustrated in figs. 1.9.3(a), (b) and (c) (using Approach 1 for localization of bearing

contact).

Approach 2 for localization of the bearing contact (with modified pinion tooth surface)

requires different setup of coordinate systems used for TCA. More details are given in Part

2 (Offset Face Gear Drives).

Transmission Errors

The transmission errors are represented by the equation

(62)

NASA/CR-2000-209909 27
In the equation above we designate with $7 the value of 4; that corresponds to c$J = 0, that
is the initial value of c$; (the position error). The value of 4; can be determined from the
numerical function &( &),;=a. The linear function $(& - $7) represents the ideal trans-
2
mission function of the face gear. The analysis of transmission errors caused by misalignment
yields the conclusion that face gear drives are not sensitive to misalignment. Using Approach
I for localization of bearing contact, it was found that the level of transmission errors is equal

to zero even for a misaligned face gear drive. In the case of Approach 2 for localization of
bearing contact (with the crowned pinion), the transmission errors for misaligned gear drives

are on the order of l/3 of an arc second, which is negligibly small (fig.l.9.4). This is an
advantage of the face gear drives in comparison with other gear drives that are used for
transformation of power between intersected or crossed axes.

NASA/CR-2000-209909 28
 Part 2
Offset Face Gear Drives (crossed axes)

2.1 General Considerations

In this part, a face gear drive used for transformation of rotation and torque between

crossed axes is considered (fig. 2.1 .l). This drive, called an 0fjcset Face Gear Drive, is an

alternative for the hypoid gear drive.

The discussion is limited to the offset face gear drive with crossing angle y = 90” (or-

thogonal face gear drive). The driving member of an offset face gear drive is an involute spur

pinion and the driven member is a face gear. The pinion and the face gear rotate about axes

z, and x2 with angular velocities w, and ~2, respectively (fig. 2.1.2). The axes of rotation

are crossed as shown in figs. 2.1.1 and 2.1.2; E is the shortest distance between the axes of

rotation of the gear and the pinion.

Generation of a face gear was covered in Part 1, Section 1.3. The same methods of

generation are applied in the case of the drive with crossed axes. The surface of the generating

shaper r,(u,, &,) and its unit normal nS(6’ kS )are given in Part 1 by equations (19) and (20).

Due to offset E of the shaper, the tooth surfaces of the generated gear will not be

symmetric (fig. 2.1.3) as they are in the case of the face gear drive with intersected axes (fig.

1.1.4). Generated surfaces of the orthogonal offset face gear are represented by the following

equations

r&, &, 44 = M&A) r&,, &,> (63)

NASA/CR-2000-209909 29
 Here and below the upper and the lower signs correspond to the surfaces that are gener-

ated by the shaper involute surfaces y - y and p---,8, respectively (fig. 1.4.1).

Equation (64) is the equation of meshing, and Mzs = MsaMahMIIS is the transformation

matrix represented by

cos $2 cos qb* - cos q& sin 4S - sin $? E cos &

- sin ~$2 cos $S sin CJ& sin c$~ - cos cp:! - E sin&
M&h) = (65)
sin $S cos 4% 0 0

0 0 0 1

Here $S and & are the angles of rotation of the shaper and the face gear, respectively, and
they are related by the following equation

$2 = $sZ (66)
After transformation, we represent face gear tooth surfaces (L) as follows:
sin &
rbs [cos fk (sin Jh $ Oks cos &) -
m2, cos Jks
+ ; cos &]
s
cos $2
r&L f%,) = -rbs [Sin $2 (Sin [ks 7 eks COS &) + (67)
m2, cos t&

where

5ks = 4s f (h., + e,,> k= W) (68)

E is the shortest center distance (figs. 2.1.1 and 2.1.2), and the following design recommen-

dation for the magnitude of E should be observed (increasing E beyond this limit on a face

gear drive with crossed axes will cause an increase in friction by sliding and an increase in

the dimensions of the face gear drive)

(69)
Nz is the number of teeth of the face gear and m is the module that is represented by

NASA/CR-2000-209909
 -
1

The bearing contact of the offset face gear drive is localized using the same principles as in

the case of the face gear drive with intersected axes (see section 1.3).

The design of offset face gear drives requires the observation of following conditions:

(1) Avoidance of undercutting and pointing of the face gear teeth.

Due to the asymmetry of the face gear tooth surfaces, the critical value of the inner radius

RI, where the undercutting of each surface occurs, must be determined. Then the dimension

of the blank used for manufacturing of the face gear is determined using the larger (more ’

critical) value of the inner radius R 1. The research results show that, for a positive offset

(E > 0) (fig. 2.1.2), the critical shaper profile is p - ,0 (fig. 1.4.1), and it is the opposite for

negative offset (E < 0).

Pointing of the o#set face gear tooth is determined by using two approaches. The first

one requires simultaneous consideration of the equations of surfaces of both sides of the face

gear tooth and the determination of the area “B” (fig. 2.1.3)) where these two surfaces

intersect each other. The other one is based on the consideration of the axis of meshing

and cross-sections of tooth profiles of the shaper and the face gear. Both approaches are

explained in detail in the following sections.

(2) Favorable relation between the tooth length ” 1 ” and the diametral pitch Pd.

The structure of a tooth of the offset face gear generated by a shaper is shown in fig. 2.1.3.

The fillets of two tooth surfaces of the face gear that are generated by the top edge of

the shaper tooth are not the same size (fig. 2.1.3). H aving a large value for the coefficient

“c”, represented by the equation (2)) it becomes possible to eliminate the part of the face

gear tooth that has a larger fillet. The elimination of the fillet surface will enable to give the

tooth of the face gear a more uniform and favorable structure, but in the same time it will

reduce the value of “c”.

.

NASA/CR-200@209909 31
2.2 Axes of Meshing

In this section the concept of axes of meshing for approximate determination of condi-
tions of pointing of the face gear is considered. The idea of axes of meshing proposed and
developed in [6], [7] and [9] 1s’ base d on the following considerations:
(1) The relative motion of gears between crossed axes may be represented by a manifold of
correlated vectors ~~‘1 and w(“), instead of vectors ~~‘1 and ,(‘,I, that represent the angular
velocities of gear rotation about the gear axes zf and xI) (fig. 2.2.1).
(2) Now, we can consider a sub-manifold of vectors ~(‘1 and w i1r! that satisfies the require-
ment that a common normal to gear tooth surfaces C, and & intersects the lines of action
of UC’) and w(I1) (fig. 2.2.2).
(3) The location and orientation of two axes of meshing may be represented by parameters
Xci), Kci)(i = I, II), where

(71)
is the direction of the axis of meshing.
Only three out of four parameters are independent, and one, say Xc’), can be chosen
deliberately. This means that in the general case there is an infinite number of correlated
axes of meshing that can be chosen for each point of tangency of surfaces E,, and C?.
(4) There is a particular case when parameters X’ii), Kci) of axes of meshing do not depend
on the location of contact point of surfaces C, and &. Such axes of meshing exist only in
particular cases and one of them is the case when one of the mating surfaces is a helicoid
whose axis coincides with the axis of gear rotation. In that case, the orientation and location
of axes of meshing are constant in the process of meshing and the common normal to C,
and & intersects both axes of meshing.
(5) In the case of face gear drives with crossed axes, the applied shaper is a spur gear that
is considered as a particular case of a helicoid with the screw parameters p, = co.

NASA/CR-2000-209909 32
 In the orthogonal oflset face gear drive the driving member is an involute spur pinion.

Based on the fact that the involute spur surface is a particular case of an involute helicoid

when the screw parameter of helicoid p, = 00, it is clear that the two axes of meshing exist.

The location and orientation of axes of meshing (fig. 2.2.3) for the orthogonal ofiset face gear

drive are determined by the following equations [6]

KU) = E _ 1 (72)
PS n-h

$1) = 0 (73)

K(“) = 0 (74)

x(“) = -E + P, (75)
m2s

Parameters Kci)(i = I, 11) designate the directions of the axes of meshing, E is the
NS
shortest center distance, p, is the screw parameter and rnTS = - is the gear ratio.
N2

Axis of meshing I - I lies in plane zh(I) = 0 (fig. 2.2.3), and according to equations (72)

and (73) its location and orientation is determined as follows

$1) = 0 (76)

KC’) = -1 (77)
m2s
Axis of meshing II - II is parallel to .zfa but lies in a plane zj:‘) that approaches to infinity

along negative direction of zfr (fig. 2.2.3). Its location and orientation are determined by

xw = -m (78)

Note that the axes of meshing can be used as an alternative approach for the derivation of

equation of meshing that was represented earlier by (64).

NASAKR-2000-209909 33
2.3 Pointing

Tooth pointing was described in Part 1, section 1.7. In this section two approaches for

determination of tooth pointing are examined in detail.

Approach 1 for Avoidance of Pointing

Pointing is determined considering the intersection of two opposite surfaces of the face

gear. Before we proceed with the determination of pointing, let us consider some character-

istics of the involute curves (surfaces).

The pitch circle is the reference dimension for tooth element proportions. The initial

point of the shaper involute curve belongs to the base circle of radius

rb,$ = rps cos a, (80)

where QI, is the pressure angle of the rack cutter that can be used for generation of the

involute curve. The value of addendum circle of a standard shaper is determined as

1.25
r (Is = rps + ~ (81)
pd

where Pd ($) is the diametral pitch.

We have to consider two cases of generation of the face gear addendum surface:

Case 1: The addendum of the face gear surface is generated as conjugated to the dedendum

involute surface of the face gear. This becomes possible when the radius r,,9 of the shaper

(fig. 2.3.1) satisfies the inequality r,,, > rbs, where

1-
r n,s = rps - (82)
Case 2: The addendum surface of the face gear consists of two sub-surfaces if r,,, < rbs as

shown in fig. 2.3.1. One of the sub-surfaces is generated as conjugated one to the dedendum

involute surface of the shaper, and the other sub-surface is generated by the fillet surface of

the shaper. Equations (80) and (82) yield r,,, 2 rbS if N, 2 1 _ :os QI . In the case when
0

NASA/CR-2000-209909 34
 2
Ns I 1 - COSCK, and two sub-surfaces of the face gear addendum surfaces are generated, we
will determine the conditions of face gear pointing taking that r,, = rbs.

To determine the exact point on the face gear surface where pointing will occur, the

following is considered:

In general, the intersection of two surfaces is a line. For determination of pointing of the face

gear tooth, the goal is to find an exact point on the line of intersection of the face gear tooth

surfaces. Such a point lies in the plane tangent to the cylinder of radius r,, and belongs to

the top (addendum) of face gear tooth. Therefore, the following equality for the orthogonal

face gear drive can be applied for each of the two sides of the face gear tooth.

(k = 7, P> (83)

The subscripts 0 and y are used for the designations of the surfaces of the face gear C, that

are generated by the shaper surfaces p and y, respectively

Substituting equation (83) into equation of face gear tooth surfaces (67), we obtain

8k, = f rms - cot 6ks

rbs sin tks

where & is represented earlier by (68).

Now, using equation (68)) we obtain the following equations for the motion parameter

4 ks

$ks = <ks =F (ok, + ‘%s) (k = 7, P> (85)

The face gear motion parameter &C,:,9j is expressed in terms of C&,-S as

hk = cbksm2s (k = 7, P) (86)

where rn2$ is the gear ratio.

Equation (67) yields

(87)

NASAKX-2000-209909 35
where (Ic = r,/?).

In order to obtain intersection of the surfaces, the following conditions are considered

Note, using the procedure described above, the system of two nonlinear equations in two

unknowns is obtained.

The system of equations (89) is solved numerically by the developed computer program

applying the subroutine for the solution of system of nonlinear equations. Then the coordi-

nates of intersection of two face gear tooth surfaces are determined, and the outer limiting

radius Rz of the face gear blank (fig. 1.1.5) is determined as

where x2 and y2 are the coordinates of the point on the face gear tooth surface where pointing

occurs.

Numerical example:

This numerical example illustrates the approach for determination of pointing, repre-

sented above. The input data is represented in Table 3

Table 3

INPUT DATA

Number of teeth of the shaper N, = 20

Number of teeth of the face gear Nz = 100

Pressure angle q, = 25”
Diametral pitch Pd = 10 (l/in)

Center distance E = 1 (in)

Crossing angle ym = 9 0

NASA/CR-2ooO-209909 36
Using above input data, the following auxiliary data is obtained:

- Gear ratio ms2 = 5

- Radius of the pitch circle of the shaper rPs = 1.0 (in)

- Radius of the shaper r,, = rPs - i = 0.9000 (in)

- Radius of the base circle of the shaper rbs = 0.9063 (in)

Since r,, < rbs it must be taken for the further calculation r,, = rbs = 0.9063 (in)

Procedure of Computations

Step 1: Equation (83) yields .z~~,B = 0.9063 (in).

Step 2: Equation (84) is used, and it is considered that the values for & and JYs are given by

the initial guess. Note that this procedure is the iterative one and the initial guess must be

provided. At the last step of iteration we have that Brs = 0.33954 (rud), and 193~ = 0.35289

(rud).

Step 2 Using equation (85), and considering as known: Jks (from the initial guess), t9ks

(from the previous step) and Oos (from the auxiliary data) the following values for $ks are

calculated: #+ = 0.26655 (rad), and $3s = -0.27704 (rad).

Step 4: Equation (86) and the known value of ms2 yield C&Z = 0.05309 (rud), and $p2 =

-0.05541 (rud).

Step 5: Then, equation (87) gives the following values for the coordinates of the gear surfaces

where pointing occurs: xzT,p = 1.0014 (in) and yzl,p = -5.77414 (in).

Equation (90) gives the following exact solution for the limiting outer radius of the face gear

R2 = 5.86034 (in).

Approach 2 for Avoidance of Pointing

It was mentioned earlier that this approach is based on consideration of the cross-sections

of tooth profiles of the shaper and the face gear. This is an alternative approximate approach,

but the results that are provided by this approach are very close to the exact one. In the

case of face gear drives with intersected axes, the instantaneous axis of rotation is used for

NASA/CR-2000-209909 37
.
determination of pointing, while in the case of the offset face gear drives the axis of meshing

is used instead.

This approach is based on the following considerations:

(1) Drawing of fig. 1.4.1 shows that, x, = 0 is the plane of symmetry of the shaper space.

At a position of the shaper when 4s = 0, coordinate system S, coincides with Sj, (fig. 2.1.2)
and the axis of meshing I - I (fig. 2.2.3) belongs to the plane x, = 0.

(2) Any cross-sections of the shaper tooth surface by planes that are parallel to x, and

perpendicular to the z,- axis represent the same involute curves. Two such planes, II, and

II?, are shown in fig. 2.3.2(u). Pl a n e II, intersects the axis of meshing I - I at a point Pi

that belongs to the axis of symmetry of the cross-section of the space of the shaper. Figs.

2.3.2(b) and 2.3.3 show points PI and P. that are the points of intersection of the axis of

meshing I - I and planes II, and I-I27 respectively.

(3) A normal to the shaper tooth surface is perpendicular to the z,- axis and therefore it

lies in plane I&, In accordance to the definition of the axes of meshing, the common normal

to the surfaces of the shaper and the face gear passes through the point of axis of meshing

Pi (i = 1,2). Points of tangency of the shaper and the face gear profiles in plane II, are

M1, M2, and N1 and NZ in plane II, (figs. 2.3.2(b) and 2.3.3). The common tangents to the

cross-section profiles form an angle cy, and Q, respectively.

(4) Now, assume that plane II2 is the plane where the pointing of the cross-section profiles of

the face gear occurs. The investigation shows that in the area where pointing is observed, the

cross-section profiles of the face gear only slightly deviate from the straight lines. Therefore,

it can be assumed that point K (fig. 2.3.3) of the intersection of the tangents to the profiles

is the point of intersection of the real cross-section profiles of the face gear.

(5) The consideration discussed above enables us to derive the equations for determination

of the outer radius & of the face gear for the zone of pointing using the following procedure.

NASA/CR-20X!-209909 38
Step 1: Vector equation (fig. 2.3.3)

----
0,A + AN, + NIK = 0,K (91)

yields that

a-tana* =Bos (92)

s
where Q,, is represented by the following equation
e
- invcx, (93)

In the above equation a:0 is the pressure angle of the shaper involute tooth.

Step Z? It is considered that point Pi belongs to the pitch cylinder of the shaper, and the

location of P2 with respect to PI is determined with segments AZ and Aq (fig. 2.3.2(u)).

Drawings of figs. 2.3.2 and 2.3.3 yield

rbs N, c o s cq, - c o s a
Aq = O,& - O,P, = -% - -=-
( > (94
c o s o! cos a, 2P.J cos Q

Al=* (95)
tan 75
Step 3: The location of plane II2 is determined with parameter Lz (fig. 2.3.2(u)), where

rP+Aq N, cos a,
La = (96)
tan 75 = 2Pd cos Q: tan 3/s
where
sin y
tany, = (97)
ms2 + cm y

In this equation y is the crossing angle and m,-3 = z is the gear ratio in meshing of the
.s
face gear and the shaper.

Finally, the outer radius R2 of the face gear is determined as

Rz = dE’ + L; (98)
.

NASA/CR-2000-209909 39
 Numerical example:

This numerical example illustrates the approach for determination of pointing, repre-

sented above. The input data is represented in Table 3

Using the input data, the following auxiliary data is obtained:

- Gear ratio: rn,? = 5

- Radius of the pitch circle of the shaper rPs = 1.0 (in)

- Angle ys = 0.197395 (rad) (see equation (97))

- Radius of the shaper rnls = rps - i = 0.9000 (in)

- Radius of the base circle of the shaper rbs = 0.9063 (in)

Since r,,,V < rbs it must be taken for the further calculation r,, = rb,s = 0.9063 (in)

- . Half of the space width on the shaper base cylinder is determined with0,,$ = O.O4856(rad)

(see equation (93))

Procedure of Computations

Step I: We use equation (92) and consider as known the following parameters of the equation:

Pd, N, (from the input data), and rms, eos (from the auxiliary data). Then, by solving

equation (92) using the subroutine for solution of nonlinear equations we obtain angle o =

0.6679 (rad) (fig. 2.3.3).

Step 2: We use equations (94) and consider as known from the input dataCtO, and Q: obtained

in Step 1. Then, we obtain Aq = 0.15436 (in) (fig. 2.3.2(a))

Step 3: Using equation (96) and considering as known TV, rPs (from the input data) and Aq

from Step 2, we obtain the length Lz = 5.7718 (in) (fig. 2.3.2(a))

Step 4: We use equations (98) and consider as known offset E (from the input data), and

L? obtained in Step 3. Then, we obtain the radius of the face gear, where pointing occurs

as R2 = 5.8578 (in).

NASA/CR-2000-209909 40
2.4 Localization of Bearing Contact and Simulation of Meshing

Two approaches for localization of the bearing contact in an offset face gear drive have

been applied.

Approach 1

This approach is based on the consideration that the pinion and the generating shaper

have different numbers of teeth. This approach has already been discussed in detail in Part

I for the case of the face gear drive with intersected axes, and therefore it is only briefly

represented in this section.

Applied coordinate systems Two movable coordinate systems Sr and S2 are rigidly con-

nected to the pinion and the gear (fig. 2.4.1 (a), (b)). Fixed coordinate systems S,,, Sf

and S, are rigidly connected to the frame. Henceforth, we will consider that all errors of

alignment are referred to the gear, and the location and the orientation of the pinion are not

affected by the errors of alignment. Auxiliary coordinate systems S, and S, are applied to

simulate the change of shortest center distance and the crossing angle. The pinion performs

rotation about the zf - axis while the gear performs rotation about the zq - axis, and their

angles of rotation are designated as $1 and 4; (figs. 2.4.1 (a), (b)). Parameter B = rps - rpp

represents the distance between the axes of the shaper and the pinion, and it depends on

AN = N, - Nr,.

Now, applying the Algorithm for simulation of meshing and contact (described in Part

I, section 1.9), and considering the equations of continuous tangency (54) and (55) of the

pinion and the face gear tooth surfaces, we can obtain the coordinates of contact points on

the gear surfaces.

Since the tangency of the surfaces must be considered in a fixed coordinate system, for

this purpose we may choose the coordinate system Sf. Then, the vector equations of the gear

and the pinion tooth surfaces (ri), as well as their unit normals (ni) have to be represented

NASACR-2000-209909 41
in S.f. The transformation matrix for coordinate transformation from the pinion to the

fixed coordinate system M,f, (equation (50)), and the transformation matrix for coordinate

transformation from the gear to the fixed coordinate system Mf, (equation (52)), are given

bY
cos 4; -sin$; 0 0

sin 4; cosqi; 0 0
= (99)
0 0 1 0

0 0 0 1

and
I-
cos $4; - sin 4; 0 -(E+ M-3) 1
I
sin Ay sin 4; sin Ay cos $‘, cos Ay B
Mf#;) = M,~.M,,M,,M,, =
- cos Ay sin 4; - cos Ay cos $1 sin Ay 0

1 0 0 0 1 1
(100)
The set of contact points represents the contact path. The contact paths and contact

ellipses for aligned and misaligned offset face gear drives are shown in figs. 2.4.2(u), (b) and

(4.

Approach 2

This approach modifies the pinion tooth surface, instead of the face gear tooth surface,

by means of a varied plunging of the tool used to generate the pinion (see section 1.3). This

section covers simulation of meshing and contact of aligned and misaligned offset face gear

drives with modified pinion tooth surfaces.

The modified tooth surfaces of the pinion are represented by the following equation

fnp(sin(8, + 6,) - 0, cos(e, + O,)]

rP (% @PI = -~bp[cos(~p + e,,) + e, sin@ + e,,)] + CLU; (101)
UP

NASA/CR-2000-209909 42
Face gear tooth surfaces generated by unmodified shaper tooth surfaces are represented by
equation (67).

Applied coordinate systems Two movable coordinate systems Sr and S, are rigidly con-

nected to the pinion and the gear (fig. 2.4.3 (a), (b)). Fixed coordinate systems S,f, S, and

S, are rigidly connected to the frame. Again, it is considered that all errors of alignment are

referred to the face gear. Auxiliary coordinate systems S, and S, are applied to simulate

misalignment. The pinion and the face gear perform rotation about the zf- and xq - axes,

and their angles of rotations are designated as 4; and 4; (figs. 2.4.3 (a), (b)). Parameter u,

(fig. 2.4.3 (a))r ep resents the distance between the axis of rotation of the face gear and the

location of the origin of the pinion coordinate system. The magnitude of u, that corresponds

to the location of the contact path in the middle of the face gear tooth length is determined

as

Here RI and & are the inner and outer radii of the face gear, obtained from the conditions

of non-undercutting and pointing, and E is the shortest center distance.

Choosing another magnitude of u,, that differs from the one determined above, we can

change the location of the bearing contact on the face gear tooth surface.

We use coordinate system Sf to consider the tangency of the contacting surfaces. Then

the vector equations of the gear and the pinion tooth surfaces (ri) as well as their unit

normals (ni) have to be represented in S,f . The transformation matrix from the pinion to

the fixed coordinate system (MfI) is given by

cos q5; - sin41 0 0

M,&$;) = sinO” cosq5; 0 0

(103)
0 1 uo
0 0 0 1

NASA/CR-2000-209909 43
 The face gear tooth surface is represented by equation (67). To represent this surface in

a fixed coordinate system, we use the following transformation matrix

cos q$ - sin $L 0 -(E + AE)

sin Ay sin (6; sin Ay cos c#$ cos Ay 0
Mdd) = M,j,M,,M,,M,, =
- cos Ay sin 4; - cos Ay cos q$ sin Ay 0

0 0 0 1
(10 >
Having the gear surfaces represented in a fixed coordinate system and applying the de-

scribed Algorithm for simulation of meshing and contact (Part 1, section 1.9), we can obtain

the set of contact points and contact ellipses. The contact path for an ideal gear drive

(gear drive without assembly errors) as well as contact paths for gear drives with simulated

misalignment are represented in fig. 2.4.4(a), (b) , (c) .

An analysis of the results for approach 2, when a pinion with a modified tooth surface is

applied, shows that the magnitude of the transmission errors (represented by equation (62))

is not equal to zero, as was the case when an unmodified pinion tooth surface was applied.

However, the magnitude of these transmission errors for a misaligned offset face gear drive

does not exceed 3 arc seconds. This leads us to the conclusion that face gear drives are

not sensitive to misalignments if the localization of the bearing contact is performed by the

application of an involute pinion with a modified surface and the same number of teeth as

the generating shaper. This approach helps to reduce the shift of the bearing contact caused

by misalignment as shown in fig. 2.4.4(a), (b), (c).

NASA/CR-2000-209909 44
 Part 3
Applications for Face Gear Drives

3.1 Design Uses for Face Gears in Aerospace Applications

Boeing has investigated several candidate aerospace applications for face gears. Use of

face gears in helicopter transmissions has been the main area of investigation, with prelim-

inary conceptual designs for several different main rotor transmission configurations having

been completed to date. Most of these concepts involve taking advantage of face gears con-

figured to split engine input torque entering the transmission as shown in figs. 1.1.2 and

1.1.3. Additional face gear arrangements were conceived for nacelle transmissions in tilt rotor

aircraft, counter-rotating NOTAR@ fan gear boxes used in helicopter antitorque systems

(see fig. 3.1 .l), lift fan propulsion gear boxes and turbo-prop gear boxes for jet aircraft. Face

gears can be used in many angular-drive applications for which bevel gears (straight or spiral

bevel) are currently used. The exception to this is with gear boxes having ratios lower than

3.5 to 1, as face gears don’t offer a significant advantage over conventional gears at lower

reduction ratios. The application of face gears in several split torque concepts is unique, as

bevel gears cannot be used in these configurations, with details of this to be described later.

3.2 Comparisons of Face Gears with Bevel Gears

Face gears have several differences with bevel gears which should be examined. Standard

face gear pinions are conventional involute spur gears, which are inexpensive to procure when

compared with bevel gears. The spur pinion has no sensitivity to axial location and only low

sensitivity to radial location. As a result of this, it is not necessary to install the pinion at a

NASA/CR-2000-209909 45
precise mounting distance, as is the case with bevel gear installations. This reduces assembly

costs and allows easy field installations of new spur pinions into gearboxes if required. Also,

no axial force is generated on the spur pinion as it meshes with the face gear. This removes

the requirement for larger bearings to handle thrust, bearings which are always required for

bevel gears. The face gear member of the set also tolerates small misalignments well, and

the misalignments cause less transmission error than in other gear forms. Like a bevel set,

the motion of a face gear set attains true conjugate action, resulting in constant velocity

shaft rotation. Basic geometric differences between these gears and bevel gears are readily

apparent, as can be seen by referring to the face gear teeth shown in figs. 1.1.1 and 1.1.3.

For the gear member of a face gear set, teeth become narrower along the top land of the

tooth as one progresses from the inside diameter (I.D.) of the gear to the outside diameter

(O.D.), and teeth widen as one goes along the tooth bottom from I.D. to O.D.. In short,

the face gear tooth has an increasing pressure angle along its length from I.D. to O.D.. The

height of the face gear teeth stays constant along their length, so that both pinion and gear

members operate along a constant base circle. In contrast, bevel gear teeth increase in both

height and width along the tooth length from I.D. to O.D.. Face gear teeth are only slightly

curved (nearly straight), both along their length and along their height, whereas spiral bevel

teeth curve significantly along both height and length.

Regarding tooth widths, the length of face gear teeth are limited by conditions of tooth

undercutting near the I.D. and tooth pointing near the O.D.. The I.D. must be greater than

the diameter at which undercutting would otherwise occur, and the O.D. must be smaller

than the diameter at which pointing would normally occur (although the O.D. can be left

somewhat larger if the top land is chamfered to remove the pointed area as shown in fig.

3.2.1). In comparison, the length of bevel gear teeth is similarly limited as a percentage of

the outer come distance, although for an equal set of basic design parameters, more bevel

gear tooth length than face gear tooth length is usually available after applying the limiting

criteria noted above. .

NASA/CR-2000-209909 46
3.3 Split Torque Face Gear Arrangements

One of the biggest advantages for using face gears is when they are applied in torque

splitting arrangements. When face gear designs are configured to allow input torque to be

divided equally from a single pinion into two face gears, the sizes of the gears involved can

be reduced substantially. This is because gear volume is proportional to the square of gear

diameter, while torque-carrying capacity of gearing is proportional to lower order determi-

nants of gear diameter (depending on whether bending or compressive stress evaluations are

being used). Therefore, if torque is reduced by approximately onehalf (based on the actual

percentage of torque split between the gears) for a load-carrying gear, the weight of the

gear can be reduced by more than one-half, due to the square relationship of weight to gear

diameter. Face gears have unique advantages over other types of angular-drive gearing when

used in specific torque splitting configurations. Two of these configurations for which this is

the case are shown in figs. 3.3.1 & 3.3.2. In particular, other types of existing gears cannot

be configured to provide an input pinion driving through angles other than ninety degrees to

two gears simultaneously. This is true whether the two driven gears face each other with one

directly above the other as shown in fig. 3.3.1, or if they are facing each other in a staggered

arrangement as shown in fig. 3.3.2. Bevel gears form cones if the pitch lines of the gear teeth

are projected out until they reach a single apex. If the shaft angle in a three member set of

one pinion driving two gears is not equal to ninety degrees (either greater or less than ninety

degrees), one of the members would have to have a cone that funnels inward (concave shape).

Bevel gears cannot be cut or ground to yield a funneled cone shape, due to manufacturing

limitations. Face gears are not restricted by this manufacturing limitation. Also, split torque

designs are almost always used in conjunction with a requirement to achieve high reduction

ratios, and face gears operate better than bevel gears at these higher ratios (see section 3.1).

NASA/CR-2000-209909 47
3.4 Design Considerations for Face Gear Usage

Special Design Considerations

The face gear design process includes some special considerations required to allow the use
of these gears. Basically, implementation of face gears into designs where bevels are typically
used is limited only by the requirement to use larger reduction ratios wherever face gears are

employed. On a more detailed level, though, several tooth geometric considerations must
be taken into account during the design process. The conditions of tooth undercutting and
tooth pointing mentioned previously in section 3.2 must be avoided. This is accomplished
by first determining at what inside radius of the gear the condition of undercutting would
occur, and at what outside radius of the gear the condition of tooth pointing would occur.
To determine these for a prospective design, the numbers of gear and pinion teeth, the
diametral pitch, the shaft angle, and the approximate amount of tooth crowning desired
must be entered as variables into known equations. Limit values for directions along both
the pitch angle and normal to the shaft centerline can be obtained. The available tooth
face width can also be obtained (also along both directions as above) from the difference
between these values. Once the face width is known, this information is considered in the
gear stress analysis along with the other design parameters. The inner and outer radius
values are utilized in design envelope considerations as well as bearing sizing and support
arrangements.

Stress Considerations

At the present time, no substantiated stress formulas are available for sizing face gear
sets in the same manner as traditional bevel or spur gear sets. Preliminary methods for
analyzing face gears have been developed at both UIC and Boeing, using a combination of
Finite Element Analysis (FEA) and modifications to existing spur gear formulas to calculate
tooth bending and tooth contact stresses for face gear sets. The analysis assumes, with

NASA/CR-2000-209909 48
substantiation from FEA, that the spur pinion is the weaker (in bending) of the two gears

in the set. Based on the FEA of models of face gear tooth geometry, it appears that the

spur pinion in a face gear set has approximately l/3 less tooth bending stress than that of

an identical spur pinion mated with a spur gear under the same loading conditions. This is

apparently due in large part to the greater contact ratio of the face gear set vs. a standard

spur set. In the traditional spur gear set, the pinion sees the load being alternately carried

by one then two teeth, whereas with a face gear set the load is carried by two or three teeth

in an alternating manner. Tooth compressive or contact stresses appear to be in the same

range as those currently found in spur gear sets, and it remains to be seen how they will

compare to spur, helical, and bevel gears after long term testing. A good discussion of the

subject of face gear stress analysis can be found in the paper “Design, Analysis, and Testing

Methods for a Split-Torque face gear Transmission” [13]. Durability tests are currently

underway at the NASA John H. Glenn Research Center to generate vibration and SN curve

data for carburized and ground face gears. These tests will also determine the characteristics

of the face gear tooth contact pattern during installation and operation. A good summary

of the most recent NASA GRC test investigations can be found in the paper “Evaluation

of Carburized and Ground Face Gears” [14]. A significant number of these durability tests

have yet to be run, and until these tests are completed, or at least much more complete, all

formulas created and used to estimate face gear stresses and lives are subject to revision,

and must be considered preliminary.

NASA/CR-2000-209909 49
References

[l] Basstein, G. and Sijtstra, A., “New Developments in Design, Manufacturing and Appli-

cations of Cylkro-( Face) Gears” , A.G.M.A. Technical Paper, 93FTM7, October 1993.

[2] Davidov, SYa., “Non-Involute Gears”, Mashgiz, 1950.

[3] Favard, J., “Course of Local Differential Geometry”, Gauthier-Villars, 1957.

w

[4] Korn, G.A. and Korn, T.M., “Mathematical Handbook for Scientists and Engineers”,

2nd edition, McGraw-Hill, New York, 1968.

[5] Litvin, F.L., “Theory of Gearing”, Nauka, 1968, (in Russian).

[6] Litvin, F.L., “Theory of Gearing”, NASA Reference Publication 1212, 1988.

[7] Litvin, F.L., “Gear Geometry and Applied Theory”, Prentice Hall, Englewood Cliffs,

NJ, 1994.

[8] Litvin, F.L., Chen, J.-S., Seol, I., Kim, D.H., Lu, J., Zhao, X., Egelja, A., and Wang, A.

G., “Computerized Design and Generation of Gear Drives with Localized Bearing Con-

tact and Low Level of Transmission Errors”, Proceedings of International Conference

on Gears, Dresden, Germany, April 22 - 24, NR. 1230, pp. 63-82, 1996.

[9] Litvin, F-L., Egelja, A., Tan, J., and Heath, G., “Computerized Design, Generation

and Simulation of Meshing of Orthogonal Offset Face-Gear Drive with a Spur Involute

Pinion with Localized Bearing Contact”, Mechanism and Machine Theory, in press.

[lo] Litvin, F.L., Wang, J.-C., Chen, Y.-J., Bossler, R.B., Heath, G., and Lewicki, D.J.,

“Face-Gear Drives: Design, Analysis and Testing for Helicopter Transmission Applica

tions”, A.G.M.A. paper, 92TFM.

NASA/CR-2000-209909 51
[ 1 l] Litvin, F.L., Zhang, Y., Wang, J.-C., Bossier, R.B., and Chen, Y.-J., “Design and

Geometry of Face-Gear Drives” , ASME J. Mechanical Design, 114: pp. 642-647, 1992(c).

[12] Litvin, F.L. and Kim, D.H., “Computerized Design, Generation and Simulation of Mesh-

ing of Involute Spur Gears With Localized Bearing Contact and Reduced Level of Trans-

mission Errors”, Transactions of ASME, Vol. 119: pp. 96-100, 1997.

[13] Chen, Y.D. and Bossler, R.B., “Design, Analysis, and Testing Methods for a Split

Torque Face-Gear Transmission”, A.I.A.A. paper 95-3051, July 1995.

[14] Lewicki, D.G., Handschuh, R.F., Heath, G.F., and Sheth, V., “Evaluation of Carburized

and Ground Face Gears”, Proceedings of the 55th American Helicopter Society Inter-

national Forum, May 1999, pp. 723-731. (Also NASA TM-1999-209188, Army Research

Laboratory Report ARL-TR-1998)

[15] Litvin, F.L., Wang, J.-C., Bossler, R.B., Lewicki, D. J., Heath, G.F., and Chen, Y.-

J., “Application of Face Gear Drives in Helicopter Transmissions”, ASME Journal of

Mechanical Design, Vol. 116(3), September 1994, pp. 672-676.

NASA/CR-2000-209909 52
I ’

Fig. 1.1.1 Face-gear drive with intersecting axes

NASA/CR-2000-209909 53
 Combining gear
/

(a1 Spiral be61 gears Engiie shaft

Combining gear

I I
I I

-
04 Face-gears

Fig. 1.1.2 Examples of torque split

NASA/CR-2000-209909 54
 Rotor shaft output

Fig. 1.1.3 Helicopter transmission with a face-gear drive

NASA/CR-2000-209909 55
 A
.

Fillet S

L’

Fig. 1.1.4 Face-gear tooth of the gear drive with intersected axes

NASA/CR-2COO-209909
Fig. 1.1.5 Schematic of a face gear

57
 1

(a 1
I

Fig. 1.2.1 Instantaneous axis of rotation OZ, pitch cones with pitch angles y1 and y2,
pitch surfaces as a cylinder rP and cone of angle y
NASA/CR-2000-209909 58
 Fig. 1.2.2 Shaper (pinion) and the face gear

59
NASA/CR-2000-209909
 2 (fa;e-gear)

Fig. 1.3.1 Generation of face gear by a shaper

NASA/CR-2000-209909 60
 Fig. 1.3.2 Imaginary tangency of the shaper and the pinion of the drive

NASA/CR-2000-209909 61
Fig. 1.3.3 Contact lines on shaper tooth surface

62
Fig. 1.3.4 Localized bearing contact

63
 Grinding
wheel

---
---

I I

Pinion ’

Fig. 1.3.5 Form grinding of the pinion with plunging of the grinding disk

NASA/CR-2000-209909 64
 ,
c

-a
c cc---

Fig. 1.3.6 Coordinate systems applied for generation of the pinion by plunging

NASA/CR-2000-209909 65
 nor faa ~erztru'im caom orrarr

. ‘u
“XL! \V
e
1 .
.
0 a *

f& bl

Fig. 1.3.7 Grinding worm proposed by E. W. Miller

NASAKX-2000-209909 66
 Fig. 1.3.8 Grinding worm proposed by F. L. Litvin et al.

NASA/CR-2000-209909 67
 Fig. 1.3.9 Dressing of the worm

NASA/CR-2OCG209909 68
 Undercutting Line

.
II I
I
\

Fig. 1.3.10 Contact lines and undercutting line of dressing shaper with N, = 28, a, = 27.5”,
E,, = 2.6799 (in); driving side
.

NASA/CR-2ooO-209909 69
 Fig. 1.4.1 Tooth profiles of the shaper

NASA/CR-2000-209909 70
 ““c
x2

9n9 XP
P2

04

Fig. 1 S. 1 Applied coordinate systems for generation of the face gear

NASA/CR-2000-209909 71
 T

I
T

Fig. 1.6.1 Limiting line L, on the shaper tooth surface

NASA/CR-2000-209909 72
 Fig. 1.6.2 Line of singular points on the face-gear tooth surface

NASA/CR-2COO-209909 73
 Fig. 1.7.1 For derivation of tooth pointing

NASA/CR-2000-209909 74
 Fig. 1.7.2 Cross section of face gear and shaper by plane II,

NASA/CR--2000-209909 75
 i

t
33

Fig. 1.7.3 Cross section of face gear and shaper by plane II,

NASA/CR-2000-209909 76
 Fig. 1.8.1 Orientation and dimensions of contact ellipse

NASA/CR-2000-209909 77
 Y!l 0
0
0 00
00
/

/
Yf

04

Fig. 1.9.1 (a), (b) Coordinate systems applied for simulation of meshing

NASA/CR-20@0-209909 78
 Y9

(4
I .

Fig. 1.9.1 (c), (d) Coordinate systems applied for simulation of meshing

NASA/CR-2000-209909 79
 Fig. 1.9.2 Tangency of surfaces in ideal gear train

NASAICR-2000-209909 80
 (a) (AN = 3, AE = 0.1 mm).

(c) (AN = 3, Ay = 0.05 “)

Fig. 1.9.3 Face gear tooth: localized bearing contact

NASA/CR-2000-209909 81
 Fig. 1.9.4 Transmission errors of face-gear drive: (a) no misalignments,
(b) AE = -0.05 mm, (c) by = -0.05 ’
NA%4/CR-2ooO-209909 82
 Fig. 2.1-l Offset face-gear drive

NASA/CR---2CKD209909 83
 xavxh XS

I
/
/
/

Fig. 2.1.2 Applied coordinate systems

NASA/CR-2000-209909 84
 .rf ace

surface

Fig. 2.1.3 Offset face-gear tooth (cross-sections of the working and fillet surface)

NASA/CR-2000-209909 85
 Fig. 2.2.1 For derivation of axes of meshing

NASA/CR-2000-209909 86
 Axis of meshing

Fig. 2.2.2 Intersection of axes of meshing by the normal to the contacting surfaces

NASA/CR-2000-209909 87
 xR ,xh
.axis of meshing

0, -
02
ZR, Z,

1z-+0=,

II

1 /
II

Fig. 2.2.3 Location and orientation of axes of meshing

NASA/CR-2000-209909 88
 Pitch circle

Fig. 2.3.1 Shaper tooth proportions

NASA/CR-2000-209909 89
 I
\ 1
2
72

\
I Al

Addendum /
line of the
face gear

OS (
A PS - ys
a> ‘I

Fig. 2.3.2 Intersection of shaper tooth surface and axis of meshing Z-Z by planes II, and II,

NASA/CR-2000-209909 90
 I p2
2a

Fig. 2.3.3 Determination of angle a where pointing of the face gear occurs

NASA/CR-2000-209909 91
 Xf x1 :

l-l B

i za
zq
AE
7
r
4

Fig. 2.4.1 (a) Applied coordinate systems for TCA (Approach 1)

NASA/CR-2000-209909 92
 Fig. 2.4.1 (b) Applied coordinate systems for TCA (Approach 1)

NASA/CR-2000-209909 93
 Fig. 2.4.2 Contact path on the face-gear tooth surface: (a) no misalignment,
(b) AE = 0.04 mm, (c) Ay = -0.05”
NASA/CR--2ooO-209909 94
 E fcGik.Xq

r______
c ?
a - -

STr Yq

Fig. 2.4.3 (a) Applied coordinate systems for TCA (Approach 2)

.

NASA/CR-2000-209909 95
 .

Xa

Fig. 2.4.3 (b) Applied coordinate systems for TCA (Approach 2)

NASA/CR-2000-209909 %
 Fig. 2.4.4 Contact path on the offset face-gear tooth surface: (a) no misalignment,
(b) AE = -0.05 mm, (c) Ay = -0.05”

NASA/CR-2000-209909 97
 CW rotation

Idler spur gears reverse rotation

Face gear #2 output shaft, CCW rotation

\
1 RX,
I b
n
I \ \ I
\ \

B
_,_._.-_-,L.-.-.-.-.C -- -.-.-.-.-.- _ b-.-.-.-
1

I
F
I I

II--1 wM,
I d //Face gear #l output shaft, CW rotation

I1

Fig. 3.1.1 Concentric face gears with dual counter-rotating output shafts

NASA/CR-2000-209909 98
 Tooth chamfer on I.D. of face gear
\ Tooth chamfer on O.D. of face gear

View of face gear teeth looking from I.D. to O.D.

Fig. 3.2.1 Face gear geometry showing tooth chamfering

NASA/CR-2000-209909 99
 Planetary carrier to output shaft

Planet gears

1x1 - 1x1

Idler spur gear (2) Lower face gear

Upper face gear I sun gear Input spur pinion (2)

Fig. 3.3.1 Concentric face gear configuration with single output shaft

NASA/CR-2000-209909 100
 Output shaft

Combining pinion (4 pl)

Combining gear (driven by face gears)

Upper face gear (2 pl)

Lower face gear (2 pl) Spur input pinion (2 pl)

(90’ or angled)

Fig. 3.3.2 Staggered (non-concentric) opposing face gear configuration

NASA/CR-2000-209909 101
 REPORT DOCUMENTATION PAGE Form Approved
OMB N o . 0704-0188
Public reporting burden for this collection of information IS estimated to average 1 hour per response, mcludlng the time for revlewng instructions, searchtng ex!stlng data sources,
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1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED
March 2000 Final Contractor Report
4. TITLE AND SUBTITLE 5. FUNDING NUMBERS

Handbook on Face Gear Drives With a Spur Involute Pinion

WU-581-30-13-00
6. AUTHOR(S) NCC3-356
lL162211A47A
FL. Litvin, A. Egelja, J. Tan, D.Y-D. Chen, and G. Heath

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS 6. PERFORMING ORGANIZATION

REPORT NUMBER
University of Illinois at Chicago
Department of Mechanical Engineering
E-12127
842 W. Taylor Street w
Chicago, Illinois 60607
3. SPONSORINGIMONITORING AGENCY NAME(S) AND ADDRESS 10. SPONSORING/MONITORING
U.S. Army Research Laboratory Defence Advanced Research AGENCY REPORT NUMBER
Cleveland, Ohio 44135-3191 Projects Agency
Arlington, Virginia 22203-I 714 NASA CR-2000-209909
NASA Glenn Research Center ARL-CR-447
Cleveland, Ohio 44135-3191

I l . SUPPLEMENTARY NOTES

FL. Litvin and A. Egelja, Gear Research Laboratory, Department of Mechanical Engineering, University of Illinois at
Chicago, 842 W. Taylor Street, Chicago, Illinois 60607; J. Tan, D.Y-D. Chen, and G. Heath, The Boeing Company,
5000 E. McDowell Road, Mesa, Arizona 85215. Responsible person, David G. Lewicki, Structures and Acoustics
Division, NASA Glenn Research Center, organization code 5950, (216) 433-3970.
l2a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE

Unclassified -Unlimited
Subject Category: 37 Distribution: Standard

This publication is available from the NASA Center for Aerospace Information, (301) 6214390.
3. ABSTRACT (Maximum 200 words)

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 are 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, compari-
sons of face gears with bevel gears, and general design considerations.

4. SUBJECT TERMS 15. NUMBER OF PAGES

107
Gears; Geometry; Contact; Design; Face-gears 16. PRICE CODE

A06
7. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT
OF REPORT OF THIS PAGE OF ABSTRACT
Unclassified . Unclassified Unclassified
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Prescribed by ANSI Std. 239-18
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