Simulation of Error-prone Continuous Generating Production Processes of Helical Gears and the Influence on the Vibration Excitation in Gear Mesh

A very important feature of high quality gears is a low noise emission in all operating conditions. Micro-geometry of the gear is of relevance for the vibration excitation in the tooth contact and significantly affected by the manufacturing process, especially the finishing operations. Besides known process related effects, uncontrolled variations such as inaccuracies in the speed synchronization of different axes or vibrations influence the surface structure of the tooth flanks. In this paper a detailed simulation of the production process is presented, providing crucial information about characteristic process properties and enabling investigations on the impact of manufacturing process on gear mesh acoustics.