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Volume 13
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

A Comprehensive Study on Meshing Performances Compensation for Face-Hobbed Hypoid Gears: Coupled Analysis of Spatial Installation Errors and Manufactured Tooth Flank Characteristics

by
Chengcheng Liang
1,*,
Yihao Zhang
1,
Longhua Liu
1,
Chaosheng Song
2 and
Siyuan Liu
2
1
School of Mechatronics and Vehicle Engineering, East China Jiaotong University, Nanchang 330013, China
2
State Key Laboratory of Mechanical Transmissions for Advanced Equipment, Chongqing University, Chongqing 400030, China
*
Author to whom correspondence should be addressed.
Machines 2025, 13(12), 1145; https://doi.org/10.3390/machines13121145
Submission received: 16 November 2025 / Revised: 4 December 2025 / Accepted: 5 December 2025 / Published: 16 December 2025
(This article belongs to the Section Advanced Manufacturing)
Versions Notes

Abstract

In manufacturing face-hobbing hypoid gears, the coupling between tooth flank errors and installation errors has a significant impact on dynamic meshing behavior, yet quantitative models for their synergistic effects remain scarce. This study elucidates the combined effects of three-dimensional (3D) installation errors and real tooth flank deviations on transmission error. First, a geometric model of the real tooth flank, incorporating midpoint pitch deviation, is established based on theoretical flank equations and coordinate transformations. Then, a finite element model integrating 3D installation errors is developed. Finally, the combined effects of installation errors and real tooth flanks on meshing performance are analyzed. Results reveal a dual role of installation errors: when compensating for midpoint pitch deviation, the peak-to-peak transmission error (PPTE) decreases by 3.78%, while the contact pattern length and area increase. Under certain conditions, despite a 26.28% increase in PPTE, the contact pattern length grows by 2.29%, accompanied by a notable reduction in maximum contact stress on the tooth flanks.
Keywords: face-hobbed hypoid gears; three-dimensional installation error; real tooth flank; meshing performance; transmission error compensation face-hobbed hypoid gears; three-dimensional installation error; real tooth flank; meshing performance; transmission error compensation

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MDPI and ACS Style

Liang, C.; Zhang, Y.; Liu, L.; Song, C.; Liu, S. A Comprehensive Study on Meshing Performances Compensation for Face-Hobbed Hypoid Gears: Coupled Analysis of Spatial Installation Errors and Manufactured Tooth Flank Characteristics. Machines 2025, 13, 1145. https://doi.org/10.3390/machines13121145

AMA Style

Liang C, Zhang Y, Liu L, Song C, Liu S. A Comprehensive Study on Meshing Performances Compensation for Face-Hobbed Hypoid Gears: Coupled Analysis of Spatial Installation Errors and Manufactured Tooth Flank Characteristics. Machines. 2025; 13(12):1145. https://doi.org/10.3390/machines13121145

Chicago/Turabian Style

Liang, Chengcheng, Yihao Zhang, Longhua Liu, Chaosheng Song, and Siyuan Liu. 2025. "A Comprehensive Study on Meshing Performances Compensation for Face-Hobbed Hypoid Gears: Coupled Analysis of Spatial Installation Errors and Manufactured Tooth Flank Characteristics" Machines 13, no. 12: 1145. https://doi.org/10.3390/machines13121145

APA Style

Liang, C., Zhang, Y., Liu, L., Song, C., & Liu, S. (2025). A Comprehensive Study on Meshing Performances Compensation for Face-Hobbed Hypoid Gears: Coupled Analysis of Spatial Installation Errors and Manufactured Tooth Flank Characteristics. Machines, 13(12), 1145. https://doi.org/10.3390/machines13121145

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