# Prediction of Machining Deformation for Split Equal-Base Circle Bevel Gear
## 1 Introduction  
Extra-large bevel gears play a crucial role in heavy industrial equipment across mining, power generation, and other sectors. Particularly, when the diameter exceeds 3000 mm, the processing methods and machining equipment become highly demanding, leading to increased complexity in testing equipment and methods. Consequently, manufacturing becomes challenging, expensive, and time-consuming. To address these challenges and facilitate transportation and machining, split straight bevel gears are widely employed in existing heavy industrial equipment. The equal-base circle bevel gear is a unique type of curved-tooth bevel gear in China [1; 2; 3]. Its machining principle is straightforward, making it particularly suitable for small machine tools to process large gears. Moreover, it is easily divisible. Hence, the large-size equal-base -bevel gear proves to be a superior alternative to the super-large straight bevel gear. Upon processing the split gear blank, engineering practices and existing data indicate that its deformation typically reaches the millimeter level [4; 5]. The main reason for this is the shape change in the response accuracy of large bevel gears. The change in stiffness and the removal of materials then play a major role in the gear blank structural deformation, causing 92.2% of total deformation. The structural deformation of the wheel blank is closely related to its section design and how to divide the overall wheel. However, the gear blank is divided first and then cut, so the deformation is large. In the existing manufacturing process, there is no design standard, and human factors have a great influence on the rational design and segmentation of gear blanks. Therefore, based on the gear blank material and the geometric gear parameters, a deformation prediction model is established, and the model is suitable for predicting the structural deformation of gear blanks, which will be very important for split equal base level gear. However, the existing research assumes that the gear blank is integral, with no exploration of internal stress changes, stiffness variations, and deformation calculations. In the research domain of split large gears, the primary focus is on large cylindrical gears, particularly emphasizing processing technology, deformation control methods, and deformation mechanisms [6]. [PERSON] et al. [7] studied the laws of internal stress changes during the machining of split-type straight bevel gears and discussed the internal deformation mechanism and laws of split-type straight bevel gears. [PERSON] et al. [8] of Zhejiang University, through theoretic calculation and ABAQUS modeling simulation, solved the deformation of a rectangular section beam under unidirectional stress in the process of delamination and studied the deformation of a large integral structure caused by residual stress of the blank after NC machining. The results show that the theoretical solution is consistent with the finite element calculation. [PERSON] et al. [9] studied the residual stress of machined parts by using the \"life and death element\" technology of finite element software and simulating stress peeling. [PERSON] et al. [10] studied the stress superposition and redistribution by establishing the finite element model of the deformed workpiece and analyzed the principle of the machining deformation of structural parts. [PERSON] et al. [11] analyzed the relationship between stress redistribution, stiffness change, and the deformation of aeronautical integral structural parts during machining and established the model to predict the deformation of integral components. [PERSON] [12] established a model for predicting machining deformation of parts with internal stress and analyzed how the initial internal stress distribution affects the deformation. [PERSON] [13] studied the effect of machining stress on part deformation during machining. [PERSON] et al. [14] established a neural network model for thin-walled parts to predict their machining errors. [PERSON] et al.