Machine-tool settings driven high-order topology optimization to grinding tooth flank by considering loaded tooth contact pattern for spiral bevel gears

In the recent spiral bevel gear grinding, the main target is to get sophisticated tooth flank optimization design having higher accuracy, efficiency and flexibility for satisfying the higher strength and less noise demands. The paper proposed an innovative collaborative optimization design considering both tooth flank geometric topography and loaded contact performance evaluation. In particular, machine-tool settings driven high-order topology optimization to grinding tooth flank is proposed by considering loaded tooth contact pattern for spiral bevel gears. Firstly, in full consideration of the high-order characteristics of universal motion concept (UMC) machine-tool settings, high-order topology expression and simulation processing modeling for NC grinding tooth flank is developed. Then, focusing on the accurate control of the point-to-point material distribution, data-driven programming of the loaded contact pattern based on numerical loaded tooth contact analysis (NLTCA) are applied to actively create the target grinding flank satisfying the geometric accuracy and loaded tooth contact pattern evaluations. Robust numerical solution to the material removal amount for matching the target grinding flank is used to get optimal machine-tool settings driven control based on sensitivity analysis. Numerical and experimental instances are provided to verify the proposed method.