Abstract:In order to further improve the grinding efficiency of face gear, this paper presents a novel method for grinding face gear along contact trace using disk CBN wheel. Firstly, the grinding principle of face gear is studied, and the tooth surface equations of rack and gear shaper cutter are derived, thus formulating the tooth surface equation of disk CBN wheel. Secondly, considering the structure of the face gear grinding machine tool and the impact of the grinding wheel parameters on the face gear tooth surface… Show more
“…31 Here, the variable transmission ratio pinion designed using the gear element method is manufactured via CNC end milling on universal multi-axis milling machines, and the prototype is shown in Figure 19. Hobbing 32,33 and grinding 34,35 are high-efficiency gear production process, while the corresponding CNC machines and tools are complex and specialized. Thus, further investigation is required.Figure 19.Prototype of the variable transmission ratio pinion.…”
Section: Manufacture Of Variable Transmission Ratio Pinion Prototypementioning
Variable transmission ratio gears have shown considerable potential as key components of variable speed transmission steering boxes that balance steering portability and sensitivity. The objective of this study is to develop a novel method for designing variable transmission ratio tooth surfaces to circumvent the shortcomings of the meshing theory method. The involute rack of the variable transmission ratio pinion-and-rack pair is considered as a set of countless and infinitely close transverse sections, each of which is referred to as a gear element. Assuming evenly distributed circles in the physical domain of the variable transmission ratio tooth surfaces of the pinion, the problem of generating a tooth surface point is transformed into solving the specific geometric feature intersection point of each circle and corresponding gear element during variable transmission ratio meshing. Thereafter, a mathematical model and algorithm are developed to generate tooth surface points in an approximately even pattern. The normal deviations of the gear-element–generated tooth surface points and the corresponding tooth surface points calculated using meshing theory show that the proposed design method has a sufficiently high accuracy. Finite element models are employed analyzing the contact pattern, contact stress, bending stress, and transmission ratio error. The results indicate that the layout of approximately even tooth surface points using the gear element method is beneficial for improving the fitting precision of tooth surfaces and reducing the contact stress and transmission ratio error. Further, the same derived law of the flank and fillet tooth surfaces is conducive to the continuity of the tooth surfaces, which contributes toward reducing the bending stress. Finally, a prototype is manufactured via CNC end milling. The major contributions lie in a robust and efficient modeling method for variable transmission ratio tooth surfaces, which combined forms a solid foundation for their application.
“…31 Here, the variable transmission ratio pinion designed using the gear element method is manufactured via CNC end milling on universal multi-axis milling machines, and the prototype is shown in Figure 19. Hobbing 32,33 and grinding 34,35 are high-efficiency gear production process, while the corresponding CNC machines and tools are complex and specialized. Thus, further investigation is required.Figure 19.Prototype of the variable transmission ratio pinion.…”
Section: Manufacture Of Variable Transmission Ratio Pinion Prototypementioning
Variable transmission ratio gears have shown considerable potential as key components of variable speed transmission steering boxes that balance steering portability and sensitivity. The objective of this study is to develop a novel method for designing variable transmission ratio tooth surfaces to circumvent the shortcomings of the meshing theory method. The involute rack of the variable transmission ratio pinion-and-rack pair is considered as a set of countless and infinitely close transverse sections, each of which is referred to as a gear element. Assuming evenly distributed circles in the physical domain of the variable transmission ratio tooth surfaces of the pinion, the problem of generating a tooth surface point is transformed into solving the specific geometric feature intersection point of each circle and corresponding gear element during variable transmission ratio meshing. Thereafter, a mathematical model and algorithm are developed to generate tooth surface points in an approximately even pattern. The normal deviations of the gear-element–generated tooth surface points and the corresponding tooth surface points calculated using meshing theory show that the proposed design method has a sufficiently high accuracy. Finite element models are employed analyzing the contact pattern, contact stress, bending stress, and transmission ratio error. The results indicate that the layout of approximately even tooth surface points using the gear element method is beneficial for improving the fitting precision of tooth surfaces and reducing the contact stress and transmission ratio error. Further, the same derived law of the flank and fillet tooth surfaces is conducive to the continuity of the tooth surfaces, which contributes toward reducing the bending stress. Finally, a prototype is manufactured via CNC end milling. The major contributions lie in a robust and efficient modeling method for variable transmission ratio tooth surfaces, which combined forms a solid foundation for their application.
“…Experiments have verified that the face gears ground by this method can obtain higher precision. Chu [16] et al proposed a method of grinding face gears along the contact trajectory using a disk-shaped CBN grinding wheel, and carried out the grinding experiment of the face gears on a five-axis grinding machine. Ming et al [2] established a finite element model grinding face gear for the temperature field with the disc grinding wheel.…”
In this paper, a transient temperature calculation model for simulating grinding face gear with a grinding worm is proposed. Firstly, according to the principle of differential geometry, the equations for determining contact arc length and contact width of the instantaneous grinding area between the worm grinding wheel and the face gear are deduced. Based on the method for the single abrasive particle cutting force and grinding heat, a mathematical model for the grinding force and grinding heat of the face gear is established, and the theoretical calculation formula of the instantaneous maximum temperature for grinding teeth of the face gear is obtained. Secondly, a finite element model of temperature field for face gear grinding with moving heat load of grinding worm wheel is established, and the influence law of grinding process parameters on tooth surface temperature is studied. Finally, the validity of the temperature field simulation model is verified by multi-group temperature testing experiments for face gear grinding.
“…Accordingly, a prototype with complex geometries can be fabricated easily [ 16 ]. Chu et al [ 17 ] proposed an efficient generation grinding method for a spur face gear along the contact trace using a disk CBN wheel. Results demonstrated that the proposed method breaks new ground for the engineering application of face gears.…”
In recent years, polymer gears have gradually become more widely employed in medium or heavy-duty conditions based on weight reduction in transmission systems because of low costs and low noise compared to metal gears. In the current industry, proposing a cost-effective approach to the manufacture of polymer gears is an important research issue. This paper investigates the wear performance of polymer gears fabricated with eight different kinds of materials using differential pressure vacuum casting and additive manufacturing techniques. It was found that both additive manufacturing and differential pressure vacuum casting seem to be an effective and cost-effective method for low-volume production of polymer gears for industrial applications. The gate number of one is the optimal design to manufacture a silicone rubber mold for differential pressure vacuum casting since the weld line of the polymer is only one. Polyurethane resin, 10 wt.% glass fiber-reinforced polylatic acid (PLA), or 10 wt.% carbon fiber-reinforced PLA are suggested for manufacturing gears for small quantity demand based on the deformation and abrasion weight percentage under process conditions of 3000 rpm for 120 min; epoxy resin is not suitable for making gears because part of the teeth will be broken during abrasion testing.
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