A method to remanufacture large-size spiral bevel gear with ease-off topology modification by face-milled generator

Spiral bevel gears are manufactured and used in pairs. When one part usually pinion fatigued, the pair will be replaced. It inevitably leads to a waste of resources and time. To solve this phenomenon, a method to remanufacture pinion with ease-off topology modification is proposed. First, the wheel and pinion were measured to fitting tooth surface, and then a conjugate surface of wheel fitting tooth surface was derived. Secondly, an ease-off topology surface was superimposed to the conjugate surface to improve mesh performance, and then a design tooth surface was obtained. Thirdly, a mathematical model to process pinion was established and original machine-tool settings parameters of pinion were calculated. The deviations between design and original tooth surface of pinion were count, and an error correction model of tooth surface was established to adjust machine-tool settings parameters. Finally, an experimental verification was conducted. The pinion was remanufactured by a face-milled generator and the mesh performance was consistent with design. The result demonstrates the method proposed is effectiveness and feasible. It provides reference for the remanufacture of large-size spiral bevel gears and has good value for engineering application.