Abstract: The relationship between machine setting parameter errors and surface errors of hypoid gears manufactured by hypoid generated modified roll(HGM)are researched. Based on the gear meshing theory, the equations of theoretical and error gear surfaces are established, the analytical expression of tooth surface processing errors caused by machine setting parameter errors is derived, and the concept of error influence coefficient is proposed, thereby the influence degree of machine setting parameter errors on surface errors can be judged. By comparison between theoretical and error gear surfaces, the change laws of tooth surface pitch point normal errors and whole tooth surface normal errors under the action of machine setting parameter errors are determined. The major impact of the machine setting parameter errors are determined by the analytical and numerical method. The content and methods of this research provide theoretical basis for and practical guidance to the compensation and correction of tooth surface errors of hypoid gears.

Key words: Difference surface, Error influence coefficient, Hypoid gear, Machine setting parameter error