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Accurate modification methodology of universal machine tool settings for spiral bevel and hypoid gears

Universal machine tool settings with higher-order motion coefficients are developed to make accurate modification considering the actual machine geometric error compensation for spiral bevel and hypoid gears. First, the universal machine tool settings are exploited for the identification of the real tooth flank form error. Furthermore, the error sensitivity analysis method and an improved Levenberg–Marquardt algorithm with a trust-region strategy are utilized to obtain the solution of modification amount. Finally, a higher-order modification methodology for the universal machine tool settings is proposed which mainly covers three vital parts: (a) optimized selection of the modification settings, (b) modification of universal machine tool settings, and (c) machine geometric error compensation. Especially, a higher-accuracy fitting method for the form error tooth flank is investigated. Some numerical examples verify that the tooth flank form error after higher-order modification can reach less than 0.5 µm or even a smaller one, and the position error after compensating process spindle can be reduced from 0.0044861° to 0.0009232°. In addition, given experimental result can validate the feasibility of the proposed methodology.