Investigation of the manufacturability of topological tooth flank modifications using adapted process kinematics for gear finish hobbing

The microgeometry of gears enables the optimization of the acoustic excitation behavior and power density of gearboxes and is applied in the form of standardized or topological tooth flank modifications in profile and flank direction. The application possibilities and limitations of manufacturing topological tooth flank modifications using gear finish hobbing have not yet been systematically investigated. The aim of this study is therefore the simulative and experimental investigation of the manufacturability of topological modifications using adapted process kinematics for gear finish hobbing. The value and the shape of the tooth flank modifications were varied. The surface topographies, profile, and flank lines of the simulated gears were validated against experimental results, revealing a high degree of correlation in both the shape and progression of the applied modifications. The maximum deviation observed between simulated and manufactured modifications was approximately 10-15%, demonstrating a high level of agreement between the simulation model and experimental results within the investigated parameter range.