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1 Introduction
Spur gears with asymmetrical teeth have been developed as a result of the search to
increase the carrying capacity of gears. In truth, the contact and bending resistance
of such gears is rising, meaning the new construct is very useful in certain cases,
e.g., for aircraft gearboxes, to name only one of many examples. The theory of the
geometrical calculation of these gears was developed more completely by Profs.
Vulgakov [1], Litvin, Lian, Kapelevich [2, 3], Novikov, Paikin, Dorofeyev,
Ananiev, Arnaudov, Dorofeyev [47], Alipiyev [8] and other scientists who have
developed various design techniques for asymmetric gears.
2 Terminology
nBasic SideDenes the width of the teeth on the operating Pitch circle.
nNAdjacent SideDenes the width of the teeth at the addendum.
The edge of a basic rack prole of the basic side is assigned. The edge of a basic
rack prole of the adjacent side is calculated by the width of the teeth on the
addendum circle.
Calculation of factor YFS of teeth for various edges of the basic and adjacent sides
is executed. The data are presented in Table 1.
Calculation of the factor YFS can be executed through a nite element method
(Figs. 2 and 3). But there is a faster, more exact way, a specially designed method
of complex integral equations [13, 14]. Diagrams for the denition of factor YFS
Fig. 2 Tooth shape factor for asymmetrical teeth with parameters corresponding to Table 1
for four basic racks are displayed in Figs. 4, 5, 6 and 7. Calculation of factor YFS
for separate basic racks is executed under the following conditions:
For the gears produced with a basic rack, n = 33 and nN = 20.
The force is applied to a tip. It is designated in Figs. by symbols Fr = Ra.
The machining method is a generating method that uses a hob without a
protuberance.
The tooth thickness is diminished by magnitude ds, equal to half of the backlash
accepted as being equal to 0.1 mm.
6 Specic Stiffness C
Fig. 3 Factor c of asymmetrical teeth with parameters corresponding to the optimal contour table
The results shown in Fig. 3 apply to gears of disk shape. Calculations are
executed with account of a backlash.
Diagrams for the denition of factor c for three basic racks are given in Fig. 3.
Factors c are described for a gear ratio u = 1. If u 1, the factor c is dened by
the formula
c0 z1; x1 c0 z2; x2
c0 2
c0 z1; x1 c0 z2; x2
Fig. 5 Asymmetrical gears. Dynamics of contact stress; Dynamics Bending stresses at driving and
driven gears
Terminology and Design of Asymmetrical Gears for Aircraft 387
Fig. 6 Asymmetrical gears. Temperature; Oil Film Thickness; Kinetics and Structure of
Transmission error
Fig. 9 HCR gears. Dynamics of contact stress; Dynamics Bending Stresses at driving and driven
gears
Terminology and Design of Asymmetrical Gears for Aircraft 389
Fig. 10 HCR gears. Temperature; Oil Film Thickness; Kinetics and Structure of Transmission error
Fig. 12 Asymmetrical gearssome of the TV7-117S turboprop engine gearbox components and
assemblies
Gears with HCR teeth have an Operating Contact Ratio >2. Advantages of HCR
gears: low vibration, low bending stress. Limitation: low oil lm thickness, man-
ufacture from heat-resisting steels of type VCS-10 (Tables 2, 3, 4 and 5).
Calculations of HCR gears are executed by means of the program
AEROFLANK. Prole errors are equal to zero.
9 Summary
The approach to the asymmetric and HCR gear design, demonstrating the basic
denition of gear teeth and mesh parameter, has been developed. Application of the
asymmetric gears in the TV7-117S, TV3-117VMA-SBM1, NK-93 turboprop
engine gearbox resulted in extremely low weight to output torque ratio, about 50 %
less in comparison with the gearboxes of its predecessors, the AI-20 and AI-24
turboprop engines. It also signicantly reduced noise and vibration levels, and cut
down the duration and expense of operational development.
Terminology and Design of Asymmetrical Gears for Aircraft 391
The new design and technological approaches that have seen realization in the
TV7-117S, TV3-117VMA-SBM1, NK-93 engine gearbox have been recommended
for the development of gearboxes of advanced aviation engines.
References