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.

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.

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.

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.

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 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.

Nonrelative sliding of spiral bevel gear mechanism based on active design of meshing line

2018 ◽  
Vol 233 (3) ◽  
pp. 1055-1067 ◽  
Author(s):  
Zhen Chen ◽  
Ming Zeng
Keyword(s):  
Design Method ◽  
Bevel Gear ◽  
Transmission Mechanism ◽  
Tooth Surface ◽  
Design Parameters ◽  
Spiral Bevel Gear ◽  
Bevel Gears ◽  
Gear Mechanism ◽  
Active Design ◽  
Spiral Bevel

In this paper, an active design method of meshing line for a spiral bevel gear mechanism with nonrelative sliding is presented. First, the general meshing line equations for a nonrelative sliding transmission mechanism between two orthogonal axes are proposed based on the active design parameters. Then, parametric equations for contact curves on the drive and driven spiral bevel gears are deduced by coordinate transformation of the meshing line equations. Further to this, parametric equations for the tooth surface of each bevel gear are derived according to the conical spiral motion of a generatrix circle along the calculated contact curves. Finally, a set of numerical examples is presented based on two types of motion equation of the meshing points. Material prototypes are fabricated and experimentally tested to validate the kinematic performance of the functionally designed spiral bevel gear set.

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.

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.

Manufacturing method of double-helical gears using CNC machining center

2015 ◽  
Vol 230 (7-8) ◽  
pp. 1149-1156 ◽  
Author(s):  
Kazumasa Kawasaki ◽  
Isamu Tsuji ◽  
Hiroshi Gunbara
Keyword(s):  
Machine Tools ◽  
Helical Gear ◽  
Cnc Machining ◽  
Tooth Surface ◽  
Design System ◽  
Helical Gears ◽  
Manufacturing Method ◽  
Machining Center ◽  
Computer Aided ◽  
Cnc Machining Center

Double-helical gears are usually manufactured using special type of machine tools, such as gear hobbing and shaping machines. In this paper, a manufacturing method of double-helical gears using a CNC machining center instead of the special type of machine tools is proposed. This manufacturing method has the following advantages: (i) the tooth surfaces can be modified arbitrarily, (ii) all we have to do in gear machining is only one machine setting, (iii) the hole and blank diameter and so on except the tooth surface can be also machined, and (iv) the auxiliary apparatus, special type of tools, and special type of machine tools are not needed. For this study, first the tooth profiles of the double-helical gear were modelled using a 3D computer-aided design system and the gear was machined using a CNC machining center based on a computer-aided manufacturing system. Next, the profile deviations, helix deviations, pitch deviations, and surface roughnesses of the manufactured double-helical gears were measured. Afterwards, the relationship between the tool wear and life time of the end mill were made clear. Finally, this manufacturing method was applied to the gears for a double-helical gear pump. As a result, the validity and effectiveness of the manufacturing method of double-helical gears using a CNC machining center were confirmed.

Theoretical and experimental analyses of spiral bevel gears with two contact paths

2017 ◽  
Vol 232 (4) ◽  
pp. 665-676 ◽  
Author(s):  
Rulong Tan ◽  
Bingkui Chen ◽  
Dong Liang ◽  
Changyan Peng
Keyword(s):  
Differential Geometry ◽  
Contact Stress ◽  
Logarithmic Spiral ◽  
Transmission Efficiency ◽  
Tooth Surface ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Generating Method ◽  
Spiral Bevel ◽  
Maximum Contact

This paper investigates the geometrical design principal of the spiral bevel gears with two contact paths from spatial conjugate curve theory. Differential geometry and gearing kinematics are introduced to derive this model. In this process, the calculation method of contact paths and tooth surface generating method are presented. According to the arguments in this paper, a process of designing the tooth surface of logarithmic spiral bevel gears with two contact paths is investigated. Then, through this process, the design of a pair of logarithmic spiral bevel gears with two contact paths is completed. Besides, the prototype is manufactured and the performance experiment is completed. Results show the maximum contact stress of spiral bevel gears with two contact paths is reduced compared to those with one contact path. Besides, the transmission efficiency of the spiral bevel gears with two contact paths can reach 98.2%.

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