DESIGN OF A COMPUTER-AIDED GEAR MANUFACTURING TOOL – RACK-SHAPED CUTTER

In this work, the calculation of Maag gear shaper cutter parameters is performed for spur gears with helical teeth in three variants – straight-tooth tool with machine offset, helical-tooth tool without machine offset and helical-tooth tool with machine offset. It is therefore a prerequisite that the manufactured involute gearing has helical teeth for each variant. The created CAD program is universal and can be used for construction in other combinations as well. The tool clamping angles on the tool holder, the cutting geometry of the cutter and the characteristic of the gearing are introduced into the calculation. The output of the work will be then calculated individual parameters of the Maag shaping cutter in the tooling system, necessary for its construction. The calculation are performed in program T-Flex CAD and the summary output is graphical 2D/3D representation of the rack-shaped cutter in its base, normal and side planes, always in a different design based on the change of the tool input data and gearing characteristic. The analysis of the tool´s involute profile was solved by vector calculus and matrices and by rotating the tool in the chosen coordinate systems. The specific calculation of the tool parameters will be solved using goniometric functions.

5-axis double-flank CNC machining of spiral bevel gears via custom-shaped tools—Part II: physical validations and experiments

Recently, a new methodology for 5-axis flank computer numerically controlled (CNC) machining, called double-flank machining, has been introduced (see “5-axis double-flank CNC machining of spiral bevel gears via custom-shaped milling tools—Part I: Modeling and simulation”). Certain geometries, such as curved teeth of spiral bevel gear, admit this approach where the machining tool has tangential contact with the material block on two sides, yielding a more efficient variant of flank machining. To achieve high machining accuracy, the path-planning algorithm, however, does not look only for the path of the tool, but also for the shape of the tool itself. The proposed approach is validated by series of physical experiments using an abrasive custom-shaped tool specifically designed for a particular type of a spiral bevel gear. The potential of this new methodology is shown in the semifinishing stage of gear manufacturing, where it outperforms traditional ball end milling by an order of magnitude in terms of machining time, while keeping, or even improving, the machining error.

Vibration signal analysis of planetary gear with amplitude, frequency and phase modulation

In this paper, the vibration signal of planetary gear with amplitude, frequency and phase modulation is studied. The proposed mathematical model is employed to in- vestigate the modulation behavior of planetary gear. Based on this model, the ampli- tude modulation (AM) sidebands are analyzed to verify the correctness of theoretical calculation by Inalpolat and Kahraman. Then, the frequency modulation (FM) side- bands and phase modulation (PM) sidebands are also illustrated through an exam- ple analysis. The effects of parameters of planetary gear such as number of planets, teeth of sun and planet phasing relationships on the AM, FM and PM sidebands are analyzed. Finally, the specific expression of transmission error, time-varying mesh stiffness and dynamic mesh force including gear manufacturing error is developed. Time history signal and acceleration spectra of gear mesh interface excitations including AM, FM and PM are investigated for the meshes of sun-planet and ring- planet. The results show that gear parameters have important influence on the mod- ulation behavior. Additionally, manufacturing errors can be introduced to predict the sidebands of planetary gear. The amplitude, frequency and phase modulation study are extremely significant for the noise and vibration reduction, especially the fault diagnosis of planetary gear

Heat Treating of EV Transmissions

As consumers embrace Electric Vehicle (EV) technology, the automotive industry is moving quickly into replacing internal combustion engines (ICE) and traditional transmissions. The change to electrically driven vehicles offers new challenges to the gear manufacturing world, and most importantly new specifications to heat treat these gears - specifically quieter gear sets and higher torque ratings. Today’s EVs have a much lower tolerance for noise from the gear set to power the vehicle; therefore, this continues the need for even quieter and stronger gears. This technical presentation will illustrate the heat treat and distortion specifications for these new gears, along with answering the “why” of selecting low pressure vacuum carburizing (LPC) for new programs around the world.

Design and Analysis of Spur Gear Using Composite Material

Spur gears are the simplest and widely used in power transmission. In recent years it is required to operate machines at varying load and speed. Gear teeth normally fail when load is increased above certain limit. Therefore, it is required to explore alternate materials for gear manufacturing. Composite materials provide adequate strength with weight reduction and they have emerged as a better alternative for replacing metallic gears. Composites provide much improved mechanical properties such as better strength to weight ratio, more hardness, and hence less chances of failure. So, this work is concerned with replacing metallic gear with composite material to improve performance of machine and to have longer working life. Efforts have also been carried out for modeling using 3D modelling software called SOLIDWORKS and finite element analysis of gears using ANSYS. Composite gears have been manufactured by stir casting, which is economical method. Composite gears offer improved properties over steel alloys and these can be used as better alternative for replacing metallic gears.

Karakterisasi hasil quenching besi cor pada manufaktur roda gigi mesin tenun

The development of science and technology today has a significant influence on technological development and advances in the industrial world. Casting is a product manufacturing technique in which the metal is melted in a furnace and then poured into a mold cavity that is similar to the original form of the cast product to be made. One of the results or products produced from the casting method in this study is a weaving gear component. The gear serves as a short distance power transmission based on the rotation ratio from the main shaft to the drive shaft. This study purpose to determine the effect of the quenching process with oil cooling media on cast iron material. The testing results reveal that the composition test results in 3.18% carbon content, such that the components in this gear manufacturing are used in cast iron, which essentially has the characteristics of being heat-resistant and brittle. It is also necessary to use it as a way of producing materials feeling the continuous impact. The brittling effect of quenching oil heat treatment improves the quality of the materials. It is observed from the research findings that use the Vickers hardness test that the quenching heat treatment shows a substantial difference in score. The highest Vickers hardness test score with quenching oil materials achieving a score of 427.84 VHN is seen. The test exhibits the maximum value of 378.18 VHN in raw materials.Keywords: Cast iron, quenching, chemical composition, Vickers hardness.

Analysis Of Tip Relief Profiles For Involute Spur Gears

The main goal of this research was to study the influence of involute spur gear tip relief on the contact stress at the engagement meshing point (the begining point of the line of contact A). Different predefined involute spur gears and modification parameters (amount and length of modification) were already available from previous studies (Schmidt 2019). In this study, both the drive and the driven gear has tip relief. The modification of the gear profile was achieved through the modification of the gear rack cutter’s profile. This way the profil modification of the gear profiles are generated during the gear generation (gear planning) process. The gears have been nitrided, so after the gear manufacturing process, the heat treatment did not defrom the modified gear profile. The gear modifications were generated in a CAD system, and the calculations were made with FEM. The results show that the tip relief influences the magnitude of the gear contact stress at the first meshig point. With the use of tip relief modification, the contact stress of the meshing gears can be reduced at the beginning of the meshing line.