1.4 Review of Gear Finishing Processes

Jain, Neelesh Kumar; Petare, Anand C.

doi:10.1016/b978-0-12-803581-8.09150-5

Cited by 12 publications

(7 citation statements)

References 31 publications

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“…Further, the total number of EIPs present in a single chain in the working space is calculated by using equation (6).…”

Section: Calculation Of Number Of Abrasive Particles Eips and Chain Structure Of Eips In Working Gapmentioning

confidence: 99%

“…The working space is 0.6 mm and the A l is calculated as 41 mm. So, the number of iron particles (N ip ) in the working gap of a single chain was found as 14 using equation (6).…”

Section: Calculation Of Number Of Abrasive Particles Eips and Chain Structure Of Eips In Working Gapmentioning

confidence: 99%

“…4,5 The second step is mainly focused on the gear tooth finishing with the specified geometry, that can be done by some conventional process like milling, shaving, and lapping. 6 In the conventional gears finishing processes, there is very little control over the abrading forces due to their rigid tools, 7 which may lead to thermal loading (gear tooth's profile burns) and excessive material removal from the surface. 8 Owing to which there is low precision in finished surfaces with poor surface integrity.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Yadav

Singh

Arora

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Fine finishing of spur gears reduces the vibrations and noise and upsurges the service life of two mating gears. A new magnetorheological gear profile finishing (MRGPF) process is utilized for the fine finishing of spur gear teeth profile surfaces. In the present study, the development of a theoretical mathematical model for the prediction of change in surface roughness during the MRGPF process is done. The present MRGPF is a controllable process with the magnitude of the magnetic field, therefore, the effect of magnetic flux density (MFD) on the gear tooth profile has been analyzed using an analytical approach. Theoretically calculated MFD is validated experimentally and with the finite element analysis. To understand the finishing process mechanism, the different forces acting on the gear surface has been investigated. For the validation of the present roughness model, three sets of finishing cycle experimentations have been performed on the spur gear profile by the MRGPF process. The surface roughness of the spur gear tooth surface after experimentation was measured using Mitutoyo SJ-400 surftest and is equated with the values of theoretically calculated surface roughness. The results show the close agreement which ranges from −7.69% to 2.85% for the same number of finishing cycles. To study the surface characteristics of the finished spur gear tooth profile surface, scanning electron microscopy is used. The present developed theoretical model for surface roughness during the MRGPF process predicts the finishing performance with cycle time, improvement in the surface quality, and functional application of the gears.

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“…Further, the total number of EIPs present in a single chain in the working space is calculated by using equation (6).…”

Section: Calculation Of Number Of Abrasive Particles Eips and Chain Structure Of Eips In Working Gapmentioning

confidence: 99%

“…The working space is 0.6 mm and the A l is calculated as 41 mm. So, the number of iron particles (N ip ) in the working gap of a single chain was found as 14 using equation (6).…”

Section: Calculation Of Number Of Abrasive Particles Eips and Chain Structure Of Eips In Working Gapmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Yadav

Singh

Arora

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…In particular, we focus on mechanical transmissions, which are widespread systems in industry, from vehicles to renewable energy, and from machine tools to automation and robotics [30][31][32][33]. Many studies focus on transmission machines from multiple perspectives, such as manufacturing and finishing [34][35][36][37][38], or metrology and tolerances [30,[39][40][41], but only a few of them deal with their design knowledge management. The studied subsystems for mechanical transmissions are both designed and manufactured by a leader multinational corporation and are definitely defined mature products with stable technologies.…”

Section: Of 19mentioning

confidence: 99%

The Systematic Design of Industrial Products through Design Archetypes: An Application on Mechanical Transmissions

2020

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Engineering design is a knowledge intensive activity for both new and mature technical systems, such as mechanical transmissions. However, design knowledge is often transferred with conservative and unstructured approaches, although knowledge management would be of the utmost importance for modern industries. In this work, we introduce a design tool, called design archetype, for collecting and managing knowledge in systematic design processes. The design archetype addresses input design requirements for different design concepts, therefore, improving awareness of the design process by interactively modifying the design solution due to different input requirements. Finally, the design archetype updates the parameters of a first embodiment computer-aided design model of the concept. A method for the development of design archetypes is presented and applied to two case studies of mechanical transmission subassemblies. The results demonstrate the effectiveness of a systematic design method based on design archetypes stored in the company database.

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“…These essential requirements could be achieved through appropriate material selection, heat treatment methods, and manufacturing processes. 9,10 The Nimonic alloy demonstrates superior performance and retains shape and size integrity at high temperature, and are also suitable for strategic applications. It is, however, hard to machine, and the machining of miniature parts is even more challenging.…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

Chaudhary

Siddiquee

Chanda³

et al. 2014

Advances in Mechanical Engineering

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Generally, gear is an essential component in various electro-mechanical devices, but its manufacturing at the micro-level is challenging. The non-conventional manufacturing processes, such as electro-discharge machining (EDM), is suitable in gear fabrication. Although miniature gears have strict accuracy requirements, the optimization of the EDM process parameters, especially for advanced materials and alloys, is critical. In this paper, Nimonic alloy miniature gears are manufactured using wire-EDM and the effect of process parameters, such as peak current, pulse-off (POFF) time, pulse-on (PON) time, wire tension, and dielectric fluid on the response factors are analyzed. The primary response factors, such as surface roughness, machining time, material removal rate, kerf width (KW), surface microhardness, and depth of microhardness are considered. Also, different dielectric fluids are prepared, which include ethylene glycol mixed demineralized water, oxygen mixed demineralized water, ethylene glycol and alumina powder mixed demineralized water, and ethylene glycol alumina powder and oxygen mixed demineralized water. Furthermore, the effect of process parameters on the multi-response using Pareto ANOVA has been analyzed. The results demonstrate that ethylene glycol mixed demineralized water, as a dielectric fluid, is the most influencing parameter to reduce the surface roughness, machining time, KW, and improve micro-hardness. Thus, dielectric fluid is an essential factor obtained from multi-response optimization followed by peak current, POFF time, wire tension, and PON time.

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1.4 Review of Gear Finishing Processes

Cited by 12 publications

References 31 publications

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

The Systematic Design of Industrial Products through Design Archetypes: An Application on Mechanical Transmissions

Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

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