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This paper delves into the generation of helical face gears using a grinding worm. It investigates the computerized generation process and explores the inherent geometric constraints associated with the application of a grinding worm for helical face gears. An approximate grinding method, tailored for helical face gears featuring large helix angles, is proposed, with an evaluation of the resulting theoretical deviations. Furthermore, a novel rapid computational approach for determining the bearing contact of helical face gear pairs is introduced and validated through Finite Element Analysis (FEA). The subsequent analysis comprehensively examines the effects of the machine tool positioning errors on tooth flank deviations, bearing contact, and transmission errors. A sensitivity matrix is developed to elucidate the relationship between machine tool positioning errors and the tooth flank deviations, leading to the proposition of a correction method for theoretical generating deviations. Finally, the paper introduces a tooth flank modification method for helical face gears and the meshing performance is highly improved. [Display omitted] • An approximate grinding method for face gear with large helix angle is introduced. • A rapid tooth contact analysis method for helical face gear pair is proposed. • The influences of positioning errors on tooth flank deviation are studied. • A correction method for tooth flank deviation of helical face gear is investigated. • The meshing performance is improved by applying tooth flank modification. [ABSTRACT FROM AUTHOR]

A semi-analytical model is first presented that thoroughly examines stress distribution patterns in inhomogeneous materials within a quarter space: a scenario of great significance and complexity observed in components such as rail-wheels, roller bearings, and gears. The model utilizes the Hetényi Image Method and Eshelby's Equivalent Inclusion Method, effectively handling the impact of inhomogeneities and satisfying the boundary conditions of the quarter space. To ensure efficient and accurate analysis, numerical techniques are incorporated, notably the Conjugate Gradient Method and the Discrete Convolution-Fast Fourier Transform algorithm. The model's validity and robustness are demonstrated through comparisons with the Finite Element Method results, displaying excellent agreement. Parametric analyses reveal that distance, depth to the free surfaces, and shape of the inhomogeneities significantly influence the results. The introduction of an edge decay coefficient, K e g , serves as a practical tool for rapid estimation of edge effects in inhomogeneous materials, significantly contributing to precise predictions of material fatigue and failure. [Display omitted] • The development of a semi-analytical model tailored for inhomogeneous materials within the quarter space is unveiled firstly. • The devised model integrates the merits of Hetényi Image Method and Eshelby's Equivalent Inclusion Method. • Leveraging the fast Fourier transformation and the Conjugate Gradient Method, the model ensures efficiency and precision. • A decay coefficient K e g is firstly proposed for a rapid estimation technique for the edge effects in inhomogeneous materials. [ABSTRACT FROM AUTHOR]