Measurement of 3D tooth flank form of hypoid gears and its usage for high quality production and performance prediction

Noise and vibration caused by inaccurate tooth flank form of hypoid gears is a big problem in automotive industry, and it becomes clear that a small deviation in tooth flank form can change gear noise considerably. The gear quality control only by tooth contact pattern is usually not sufficient. High precision measurement of geometrical accuracy of tooth flank form of hypoid gears becomes recently possible not only by point-to-point measuring method but also by scanning tooth flanks. The method of usage of measured data of tooth flank form of hypoid gears for high quality production of gears and performance prediction is introduced. Performance simulation program of hypoid gears that can accepts measured form deviation of real tooth flank form is developed. Some simulated results are compared with actual results in fields and experiences, and the effectiveness of the measurement of tooth flank form accuracy of hypoid gears is discussed.