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The tooth surface error will affect the contact pattern and transmission error of the hypoid gear, which may result in an unfavorable dynamic response. The tooth surface error can be generated by machine tool errors, such as blade wear. The most common forms of blade wear are the positive cutter radius and the positive blade angle error. In addition, in the cutting process of face-hobbed hypoid gear, the continuous indexing motion will aggravate the blade wear due to the alternating cutting force. Most previous studies on the influence of hypoid gear tool errors only focus on the contact pattern and static transmission error. However, there are very few studies about the effect of tool errors on hypoid gear dynamic responses. In this paper, a hypoid gear tooth surface, mesh, and linear dynamic model with tool errors were established. The tooth surface deviation distribution of different tool errors was analyzed.

The vehicle axle gear whine noise and vibration are key issues for the automotive industry to design a quiet, reliable driveline system. The main source of excitation for this vibration energy comes from hypoid gear transmission error (TE). The vibration transmits through the flexible axle components, then radiates off from the surface of the housing structure. Thus, the design of hypoid gear pair with minimization of TE is one way to control the dynamic behavior of the vehicle axle system. In this paper, an approach to obtain minimum TE and improved dynamic response with optimal tooth profile modification parameters is discussed. A neural network algorithm, named Back Propagation (BP) algorithm, with improved Particle Swarm Optimization (PSO) is used to predict the TE if some tooth profile modification parameters are given to train the model.

The meshing noise of hypoid gear has a significant influence on driving axle system. It should be strictly controlled in order to reduce the whole vehicle noise. Meshing internal excitation of hypoid gear is a main source of vibration noise, closely connected with geometrical shape and meshing status. There is no comprehensive analysis on the impact of various contact patterns on vibration noise in previous studies. Therefore, the method for controlling contact characteristics of hypoid gears is studied in this paper, which includes adjusting the position and length of contact pattern, direction of contact trace and the theoretical transmission error. Also, a non-linear dynamic model with multi-freedom for the hypoid gear pair of the driving axle is established to evaluate the dynamic response of the gear pair. Then an example was carried out to improve the dynamic characteristic of hypoid gears by tooth profile modification.

Gear drives are widely used in the transmission of many types of vehicles and various gear faults were reported to have different effects on the performance of transmission systems. The psychoacoustics metrics, which are used to represent the human hearing property, are objective indicators of product sound quality performance. Therefore, psychoacoustic analysis of gear noise with gear faults needs to be conducted. In this paper, different types of gear faults are summarized, and two of them, including wear and misalignment, are studied separately in the psychoacoustic analysis of the synthesized noise signal of an example gearbox. The gear noise spectra for the cases with different gear faults are synthesized based on the findings of previous publications, where it shows that the two gear faults can either increase the amplitude at the harmonics of the gear mesh frequency or cause the sideband responses.