In many cases, gear honing represents a costefficient process for gear manufacturers. Another advantage of gear honing is the generation of a surface structure on the tooth flank which improves the noise behavior of the gear. Previous research activities have resulted in reliable gear honing processes, particularly for automotive gears with a tip diameter of up to 150 mm. Problems occur, however, when honing larger gears with a tip diameter of more than 150 mm, thereby rendering a robust manufacturing process is difficult. In the course of this paper, an analysis will be carried out of the geometrical and kinematic conditions that will lead to a better understanding of the process. The aim of this report is to provide an overview of the current basic conditions of the gear honing process. Theoretical studies are conducted to identify differences in gear honing processes with various tip diameters. This analysis forms the basis for optimizing process design, with the aim of generating a cost-efficient gear honing operation for gears with a tip diameter of more than 150 mm.
The desire for general purpose computation on graphics processing units caused the advance of new programming paradigms, e.g. OpenCL C/C++, CUDA C or the PGI Accelerator Model. In this paper, we apply these programming approaches to the software KegelSpan for simulating bevel gear cutting. This engineering application simulates an important manufacturing process in the automotive industry. The results obtained are compared to an OpenMP implementation on various hardware configurations. The discussion covers performance results, but also productivity of code development realized in this effort.
Gear finish hobbing is a method for soft finishing of external cylindrical power transmission gears. The application of this process is required when the process chain of gear production is to be set up completely free of coolant. Since this finishing technology is relatively new, there is some practical experience, but no fundamental knowledge regarding economical process design. One challenge in process design is that unbalanced tool wear typically leads to geometrical deviations of the machined gear profile. The aim of the investigations described in this paper is to develop a wear model which is capable to predict the local tool wear of gear finish hobbing tools. This model is based on analogy cutting trials and geometrical analyses of the chip geometries in gear finish hobbing. The results of the model are validated by flycutting trials with different local loads on the tool. The validation shows that an optimization of the local tool wear development can be achieved by means of the prediction model. Therefore, an optimization of the technological process parameters can be carried out based on this model to reach an efficient process design.
Beveloid gears, also known as conical involute gears, gain more and more importance in industrial practice. They are based on cylindrical gears but have a variable addendum modification along their tooth width. For marine transmissions beveloids are already deployed for a longer period, but there is a growing interest in this type of gears on the part of the automobile industry. Unfortunately the behavior of beveloid gears is not as well understood as the behavior of spur or bevel gears. Therefore the possibilities to evaluate these behaviors have to be enhanced. This paper shows a manufacturing simulation of beveloid gears and the usage of the generated geometries in a general tooth contact analysis program.
Due to generally reducing the noise level of machines and automotive applications gear noise optimization becomes more important. To optimize the excitation of the gearing in the development process, tooth contact analysis software is used. The transmission error is most common to characterize the noise excitation of gear sets. Usually in automotive applications gear noise is influenced by the entire drive train system with all its components. Therefore, it is necessary to asses if the transmission error of the gear set correlates to the noise of the drive train. Aim of a project funded by the German Research Foundation (DFG) was to investigate the possibility to measure the transmission error for every step of assembly. The transmission error was measured for a gear set, the transmission and the drive train. The research object was the drive train of a light truck. This report presents the results of the completed project.
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