Research on the NC Machining and Simulation for Spiral Bevel Gears of Half-Spread-Out Helix Modified Roll

2018 ◽  
Vol 939 ◽  
pp. 63-72
Author(s):  
Xi Ning Jiang ◽  
Yue Hai Sun ◽  
Xiao Hu Xie
Keyword(s):  
Cnc Machining ◽  
Numerical Control ◽  
Tooth Surface ◽  
Numerical Control Machining ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Machining Center ◽  
New Type ◽  
Spiral Bevel ◽  
Five Axis

A new type of machining method called half-spread-out helix modified roll is used to carry out numerical control machining and simulation of spiral bevel gears in this paper. The transformation from traditional machine tool adjustment parameters into processing input parameters of five-axis CNC machining center was realized. The simulated gear model of this machining method is obtained, and the coordinates of its tooth surface points are compared with points coordinates of theoretical tooth surface which are generated according to the traditional machining method. From the comparison, the correctness of this numerical control machining model is verified.

Polishing of Large-Sized Spiral Bevel Gears Using Radial Bristle Brush

2017 ◽  
Vol 873 ◽  
pp. 48-53
Author(s):  
Kazumasa Kawasaki ◽  
Isamu Tsuji
Keyword(s):  
Surface Roughness ◽  
Cnc Machining ◽  
Numerical Control ◽  
Tooth Surface ◽  
Poly Vinyl Alcohol ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tool Mark ◽  
Tooth Surfaces ◽  
Spiral Bevel

A machining method of large-sized spiral bevel gears in cyclo-palloid system has been developed using a computer numerical control (CNC) machining center. As a result of trial machining, the tooth surfaces were rough and leprous tool mark occurred. Therefore, the tooth surfaces were polished using a poly-vinyl alcohol (PVA) elastic grindstone after machining in order to improve the surface roughness and the occurrence of leprous tool mark. However, the wear and clogging of the elastic grindstone occurred after polishing. In this paper, the tooth surfaces of the large-sized spiral bevel gears are polished using a radial bristle brush instead of a PVA elastic grindstone. The swarf cutting that was machined by the side of a tool was carried out in polishing in order to make the life of the radial bristle brush. After polishing, the tooth surface was observed and the surface roughness was measured. Afterwards, the surface roughness and the occurrence of leprous tool mark before and after polishing were compared. As a result, the surface roughness and the occurrence of leprous tool mark were improved.

scholarly journals Remanufacturing the Pinion: An Application of a New Design Method for Spiral Bevel Gears

2014 ◽  
Vol 6 ◽  
pp. 257581 ◽  
Author(s):  
Baozhen Lei ◽  
Guang Cheng ◽  
Harald Löwe ◽  
Xunwei Wang
Keyword(s):  
Design Method ◽  
Cnc Machining ◽  
Tooth Surface ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Machining Center ◽  
Special Machine ◽  
Tool Surface ◽  
Spiral Bevel ◽  
Cnc Machining Center

Damages of a large spiral bevel gear drive as used in heavy industry typically affect the pinion. Even if the gear still could be used, the complete pair has to be changed. This leads to long off times, high costs, and unnecessary waste. This paper applies a recent design technology for spiral bevel gears to the production of a replacement pinion for the sake of energy saving, reduction of costs and off times, and for the realization of green engineering. The process involves the following steps. First, the real tool surface of the gear is measured by a CMM. Based on the new design method, the tooth surface of the mating pinion is derived from this discrete point cloud. In order to improve the meshing performance, the resulting surface of the pinion is modified in the third step. Finally, the pinion is produced on a CNC machining center. In contrast to other approaches, none of these steps needs the parameters of the special machine tool defining the original gear pair. It is worth noting that our technology can also be profitable to gain more freedom in the design of new gear pairs.

Mathematical Modeling and Simulation of the External and Internal Double Circular-Arc Spiral Bevel Gears for the Nutation Drive

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Ligang Yao ◽  
Bing Gu ◽  
Shujuan Haung ◽  
Guowu Wei ◽  
Jian S. Dai
Keyword(s):  
Mathematical Modeling ◽  
Numerical Control ◽  
Tooth Surface ◽  
Circular Arc ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Nc Simulation ◽  
Helical Angle ◽  
Nc Milling ◽  
Spiral Bevel

The purpose of this paper is to propose a pair of external and internal spiral bevel gears with double circular-arc in the nutation drive. Based on the movement of nutation, this paper develops equations of the tooth profiles for the gear set, leading to the mathematical modeling of the spiral bevel gear with a constant helical angle gear alignment curve, enabling the tooth surface to be generated, and permitting the theoretical contacting lines to be produced in light of the meshing function. Simulation and verification are carried out to prove the mathematical equations. Numerical control (NC) simulation of machining the external and internal double circular-arc spiral bevel gears is developed, and the spiral gears were manufactured on a NC milling machine. The prototype of the nutation drive is illustrated in the case study at the end of this paper.

Manufacture of Optimized Face-Hobbed Spiral Bevel Gears on Computer Numerical Control Hypoid Generator

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Vilmos V. Simon
Keyword(s):  
Machine Tool ◽  
Angular Displacement ◽  
Transmission Error ◽  
Numerical Control ◽  
Tooth Surface ◽  
Surface Geometry ◽  
Tooth Contact ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Spiral Bevel

In this study, a method is proposed for the advanced manufacture of face-hobbed spiral bevel gears on CNC hypoid generators with optimized tooth surface geometry. An optimization methodology is applied to systematically define optimal head-cutter geometry and machine tool settings to introduce optimal tooth modifications. The goal of the optimization is to simultaneously minimize tooth contact pressures and angular displacement error of the driven gear (the transmission error). The optimization is based on machine tool setting variation on the cradle-type generator conducted by optimal polynomial functions. An algorithm is developed for the execution of motions on the CNC hypoid generator using the relations on the cradle-type machine. Effectiveness of the method was demonstrated by using a face-hobbed spiral bevel gear example. Significant reductions in the maximum tooth contact pressure and in the transmission errors were obtained.

Generation of Noncircular Spiral Bevel Gears by Face-Milling Method

2016 ◽  
Vol 138 (8) ◽  
Author(s):  
Fangyan Zheng ◽  
Lin Hua ◽  
Dingfang Chen ◽  
Xinghui Han
Keyword(s):  
Face Milling ◽  
Cnc Machining ◽  
Tooth Surface ◽  
Free Form ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Milling Method ◽  
Spiral Bevel ◽  
Crown Gear

Noncircular bevel gears are applied in variable-speed transmissions with intersecting axes. Since dedicated machines for manufacturing noncircular bevel gears are not available, noncircular bevel gears are normally manufactured using universal computer numerically controlled (CNC) machining centers, resulting in poor productivity. This paper describes a face-milling method for generation of noncircular spiral bevel gears, which is analogous to the generation of spiral bevel and hypoid gears using CNC hypoid gear generators, such as Gleason free-form hypoid generators. As a result, the productivity is significantly improved. Based on the theory of gearing, this paper first describes the basic concept of generation of conjugate noncircular spiral bevel gears. Generation of the tooth surfaces using crown-gear generation concept is analytically discussed with association to the face-milling process of generation of the proposed noncircular spiral bevel gears. The tooth surface geometries are represented by the position vectors and normals. The kinematical model of free-form machines is developed. The machine motion parameters are determined based on the theoretically defined tooth surfaces using the crown-gear generation concept. The developed method is verified by manufacturing a real pair of noncircular spiral bevel gears with satisfactory contact patterns which agree well with those modeled using a commercial cae software program.

scholarly journals An Efficient Approach to the Five-Axis Flank Milling of Non-Ferrous Spiral Bevel Gears

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 4848
Author(s):  
Hao Xu ◽  
Yuansheng Zhou ◽  
Yuhui He ◽  
Jinyuan Tang
Keyword(s):  
Contact Area ◽  
Tool Path ◽  
Closed Form Solution ◽  
Tooth Surface ◽  
Flank Milling ◽  
Machining Accuracy ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Spiral Bevel ◽  
Five Axis

Five-axis flank milling has been applied in industry as a relatively new method to cut spiral bevel gears (SBGs) for its flexibility, especially for the applications of small batches and repairs. However, it still has critical inferior aspects compared to the traditional manufacturing ways of SBGs: the efficiency is low, and the machining accuracy may not ensure the qualified meshing performances. To improve the efficiency, especially for cutting non-ferrous metals, this work proposes an approach to simultaneously cut the tooth surface and tooth bottom by a filleted cutter with only one pass. Meanwhile, the machining accuracy of the contact area is considered beforehand for the tool path optimization to ensure the meshing performances, which is further confirmed by FEM (finite element method). For the convenience of the FEM, the tooth surface points are calculated with an even distribution, and the calculation process is efficiently implemented with a closed-form solution. Based on the proposed method, the number (or total length) of the tool path is reduced, and the contact area is qualified. Both the simulation and cutting experiment are implemented to validate the proposed method.

A New Method of Designing the Tooth Surfaces of Spiral Bevel Gears With Ruled Surface for Their Accurate Five-Axis Flank Milling

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
Yuansheng Zhou ◽  
Zezhong C. Chen ◽  
Jinyuan Tang
Keyword(s):  
Ruled Surface ◽  
New Method ◽  
Tooth Surface ◽  
Flank Milling ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Gear Manufacturing ◽  
Spiral Bevel ◽  
Five Axis

The advantages of the five-axis flank milling of (developable) ruled surfaces include that (1) the machined surfaces could be very accurate and smooth and (2) the machining efficiency is high. Currently, spiral bevel gears are machined on the machine tools specially used for gear manufacturing. The disadvantages are that the cost is high for small batch, prototype, or repair. If a small group of spiral bevel gears are needed, the current methods are not valid. Thus, it is expected to machine the gears on five-axis computer numerical control (CNC) milling centers. Unfortunately, when tooth surfaces are designed based on the conventional gear manufacturing methods, they cannot be accurately machined in five-axis flank milling. This work is to develop the new technique for the five-axis flank milling of spiral bevel gears. First, a new method of designing the tooth surface of spiral bevel gears with ruled surface is proposed. Second, the cutter locations and orientations are calculated for five-axis flank milling the tooth surfaces. Third, the actual tooth surfaces are accurately represented with the cutter envelope surface in five-axis flank milling. It is confirmed that the difference of the actual tooth surface and the designed tooth surface is within the tolerance. Then, a pinion is generated to mesh with the gear, and the tooth contact analysis (TCA) is conducted. The good result demonstrates that the proposed method is valid, thus it can be used in industry.

Manufacturing Method of Long-Cone-Distance Spiral Bevel Gears Based on CNC Machining Center

2011 ◽  
Vol 86 ◽  
pp. 889-892 ◽  
Author(s):  
Bao Zhen Lei ◽  
Bin Zhang ◽  
Hua Zhang
Keyword(s):  
Machine Tool ◽  
Geometric Modeling ◽  
Cnc Machining ◽  
Spiral Bevel Gears ◽  
Manufacturing Method ◽  
Bevel Gears ◽  
Machining Center ◽  
Spiral Bevel ◽  
Cam Software ◽  
Cnc Machining Center

A method is presented for producing long-cone-distance spiral bevel gears using CNC machining center. Due to long-cone-distance, these spiral bevel gears are very difficult to produce, because machine-tool settings exceed the outermost limits of the available dedicated machines. The method removes the limits of the dedicated machine tool. This paper consists of (a) geometric modeling of the long-cone-distance spiral bevel gears, (b) process planning for NC machining based on CAM software. Experimental cuts were made to ascertain the validity and effectiveness of the presented method with a CNC machining center.

scholarly journals Lubrication characteristics of gear after shot peening base on 25-pellet model

2018 ◽  
Vol 10 (7) ◽  
pp. 168781401879065 ◽  
Author(s):  
Shuai Mo ◽  
Shengping Zhu ◽  
Guoguang Jin ◽  
Jiabei Gong ◽  
Zhanyong Feng ◽  
...  
Keyword(s):  
Shot Peening ◽  
High Speed ◽  
Target Material ◽  
Bevel Gear ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Spiral Bevel ◽  
Lubrication Characteristics

High-speed heavy-load spiral bevel gears put forward high requirement for flexural strength; shot peening is a technique that greatly improves the bending fatigue strength of gears. During shot peening, a large number of fine pellets bombard the surface of the metal target material at very high speeds and let the target material undergo plastic deformation, at the same time strengthening layer is produced. Spiral bevel gear as the object of being bombarded inevitably brought the tooth surface micro-morphology changes. In this article, we aim to reveal the effect of microtopography of tooth shot peening on gear lubrication in spiral bevel gear, try to establish a reasonable description of the microscopic morphology for tooth surface by shot peening, to reveal the lubrication characteristics of spiral bevel gears after shot peening treatment based on the lubrication theory, and do comparative research on the surface lubrication characteristics of a variety of microstructures.

Kinematical Optimization of Spiral Bevel Gears

1992 ◽  
Author(s):  
Zhang-Hua Fong ◽  
Chung-Biau Tsay
Keyword(s):  
Mathematical Model ◽  
Bevel Gear ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Tooth Contact ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Contact Patterns ◽  
Spiral Bevel ◽  
Kinematic Errors

Abstract Kinematical optimization and sensitivity analysis of circular-cut spiral bevel gears are investigated in this paper. Based on the Gleason spiral bevel gear generator and EPG test machine, a mathematical model is proposed to simulate the tooth contact conditions of the spiral bevel gear set. All the machine settings and assembly data are simulated by simplified parameters. The tooth contact patterns and kinematic errors are obtained by the proposed mathematical model and the tooth contact analysis techniques. Loaded tooth contact patterns are obtained by the differential geometry and the Hertz contact formulas. Tooth surface sensitivity due to the variation of machine settings is studied. The corrective machine settings can be calculated by the sensitive matrix and the linear regression method. An optimization algorithm is also developed to minimize the kinematic errors and the discontinuity of tooth meshing. According to the proposed studies, an improved procedure for development of spiral bevel gears is suggested. The results of this paper can be applied to determine the sensitivity and precision requirements in manufacturing, and improve the running quality of the spiral bevel gears. Two examples are presented to demonstrate the applications of the optimization model.

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