Digital twin modeling for tooth surface grinding considering low-risk transmission performance of non-orthogonal aviation spiral bevel gears.

Low-risk transmission performance including elastic deformation, loaded contact pattern, load distribution and loaded transmission error is of paramount significance to the actual manufacturing for non-orthogonal aviation spiral bevel gears. The advanced digital twin technology is introduced into tooth flank grinding. A new digital twin modeling considering low-risk transmission performances is proposed. In the modeling, low-risk transmission performance driven simulation, sensitivity analysis and robust control are developed, respectively Firstly, data-driven tooth surface modeling is developed by simulating free-form tooth surface grinding including gear tilt method and pinion double helical method. With local geometric boundary setup meshing stiffness is determined by using local Rayleigh-Ritz solution. Then, to deal with the sensitivity of gear assembly, an improved tooth contact analysis (TCA) is developed. Moreover, numerical loaded tooth contact analysis (NLTCA) is performed to build a bridge between of low-risk performances and hypoid generator parameters. The low-risk transmission performance driven control model is established by using hypoid generator parameters modification. Finally, sensitivity analysis strategy-based robust control model is solved by using Levenberg-Marquardt method for accurate hypoid generator parameters having modification amount. The provided numerical instance can verify the proposed method.
Competing Interests: Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
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