Abstract
Presented is a generalized methodology for the integrated design and manufacture of hyperboloidal gear pairs. This methodology is applicable for any gear type where spur, helical, bevel, worm, spiroid, hypoid, and non-circular gears are special cases of a generalized hyperboloidal gear pair. A survey of existing methods for hypoid gear design and manufacture are discussed to illustrate certain deficiencies inherent in present day methods for gear design and manufacture. A brief discussion of cylindroidal coordinates is given along with examples of various gear types to demonstrate the versatility of this special system of curvilinear coordinates for the synthesis of generalized gear pairs. Subsequently, design rating parameters of such generalized hyperboloidal gear elements are included to evaluate candidate gear pairs. These rating parameters include maximum Von Mises fillet stress, tooth surface contact stress, coefficient of friction, flash temperature, lubricant film thickness, and instantaneous tooth mesh losses.
