Manufacturing Method for Large Cylindrical Worm Gear Set of ISO Type I on Universal CNC Machine Tools

Kawasaki, Kazumasa; Tsuji, Isamu

doi:10.3390/jmmp7020053

Cited by 3 publications

(3 citation statements)

References 40 publications

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“…By modeling the targeted theoretical tooth sides of the complicated worm gear that fits the cylindrical worm in the three-dimensional CAD software, and by manufacturing the worm gear using a CAM process, and then comparing the contact patterns of the experimental and analytical teeth, it can be concluded that they can be considered to be of the same approximation as required in the industry, and as a result, the manufacturing method has been already validated [79]. The selection of projections is decisive for examining changes in shape and kinematic geometry during machining with high-feed face milling, since at low feed, the effect of the material forming of the side edge has been the most critical, the chip becomes deformed perpendicular to it, while the primary part of chip removal gradually moves to an edge perpendicular to the tool axis as the feed increases.…”

Section: Discussionmentioning

confidence: 99%

Challenges of Engineering Applications of Descriptive Geometry

Balajti

2023

Symmetry

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Descriptive geometry has indispensable applications in many engineering activities. A summary of these is provided in the first chapter of this paper, preceded by a brief introduction into the methods of representation and mathematical recognition related to our research area, such as projection perpendicular to a single plane, projection images created by perpendicular projection onto two mutually perpendicular image planes, but placed on one plane, including the research of curves and movements, visual representation and perception relying on a mathematical approach, and studies on toothed driving pairs and tool geometry in order to place the development presented here among them. As a result of the continuous variability of the technological environment according to various optimization aspects, the engineering activities must also be continuously adapted to the changes, for which an appropriate approach and formulation are required from the practitioners of descriptive geometry, and can even lead to improvement in the field of descriptive geometry. The imaging procedures are always based on the methods and theorems of descriptive geometry. Our aim was to examine the spatial variation in the wear of the tool edge and the machining of the components of toothed drive pairs using two cameras. Resolving contradictions in spatial geometry reconstruction research is a constant challenge, to which a possible answer in many cases is the searching for the right projection direction, and positioning cameras appropriately. A special method of enumerating the possible infinite viewpoints for the reconstruction of tool surface edge curves is presented in the second part of this paper. In the case of the monitoring the shape geometry, taking into account the interchangeability of the projection directions, i.e., the property of symmetry, all images made from two perpendicular directions were taken into account. The procedure for determining the correct directions in a mathematically exact way is also presented through examples. A new criterion was formulated for the tested tooth edge of the hob to take into account the shading of the tooth next to it. The analysis and some of the results of the Monge mapping, suitable for the solution of a mechanical engineering task to be solved in a specific technical environment, namely defining the conditions for camera placements that ensure reconstructibility are also presented. Taking physical shadowing into account, conclusions can be drawn about the degree of distortion of the machined surface from the spatial deformation of the edge curve of the tool reconstructed with correctly positioned cameras.

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Section: Discussionmentioning

confidence: 99%

Challenges of Engineering Applications of Descriptive Geometry

Balajti

2023

Symmetry

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“…The manufacturing processes of screw-shaped parts mainly include cutting (milling and grinding), solid plastic forming, casting, additive manufacturing forming, etc. Additionally, these processes can also be used in the production of long-axis complex profile parts such as worm gear and steering gear components, high-pressure common rail pipes, crankshafts, gear racks and gear shafts [57][58][59], which are shown in Figure 14. Among the above processes, the main manufacturing method adopted by many enterprises is the cutting process, which has the advantages of overall manufacturing and a short process flow, but it has the following obvious shortcomings:…”

Section: Summary Of Common Screw Manufacturing Processesmentioning

confidence: 99%

“…Sci. 2024, 14, x FOR PEER REVIEW 11 of 19 crankshafts, gear racks and gear shafts [57][58][59], which are shown in Figure 14. Among the above processes, the main manufacturing method adopted by many enterprises is the cutting process, which has the advantages of overall manufacturing and a short process flow, but it has the following obvious shortcomings:…”

Section: Summary Of Common Screw Manufacturing Processesmentioning

confidence: 99%

Research Progress on the Manufacturing of Screw-Shaped Parts in Screw Compressors

Wang,

Xiong,

Feng

et al. 2024

Applied Sciences

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Screw compressors are highly researched and developed prospects in industry because of their long service life, high transmission efficiency, low footprint and low vibration. As the key core part of the screw compressor, the screw is a typical, long-shaft, complex profile part. Its processing method, manufacturing accuracy and quality have an extremely important impact on the performance of the whole screw compressor. In this work, the research progress on the manufacturing of screw-shaped parts in screw compressors is summarised from the aspects of the cutting process, solid plastic forming, casting and additive manufacturing. The merits and demerits of these manufacturing processes are provided and discussed, which is conducive to the development of the high-efficiency, precise and high-performance forming process of screw-shaped parts. Additionally, a novel forming process is proposed to solve the problems of serious material waste and low production efficiency for the screw-shaped parts. In the proposed process, the semi-solid spherical grain is firstly prepared by radial forging and the isothermal treatment of long-shaft raw materials. The large strain energy can be stored in the bar by the radial forging of long-shaft raw materials, which is used to induce the generation of semi-solid spherical grains with the assistance of the isothermal procedure. After that, the screw is fabricated by the high-efficiency semi-solid closed extrusion process.

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Generalization Process of the Integrated Mathematical Model Created for the Development of the Production Geometry of Complicated Surfaces

Balajti

2024

Symmetry

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Computer modelling of technical constructions is increasingly carried out using software that includes more detailed knowledge, which requires an increase in the level as well as an expansion of the scope of the geometric knowledge. A significant part of motion transmission mechanisms are worm drive pairs, for which the separation of the parts dealing with the theoretical and practical problems found in the literature can be experienced in numerous instances. Due to the different technical features, in many cases the helical surfaces are not designed and manufactured in a geometrically correct way, or the best solution is not the compulsory chosen. The geometric model describing the production process of the worm surfaces provides the basis for examining the deviation between the surface mathematically determined by the designer and the surface produced. An integrated mathematical kinematic model was developed for the production geometrical analysis of the elements of cylindrical and conical worm gear drive pairs for machining with a traditional thread grinding machine, which causes a serious pitch fluctuating error among several other problems in the case of machining the conical worm. Modelling of the production process of surfaces and the simultaneous study of the manufacturing errors is basically performed with the toolbox of descriptive geometry, including the use of the projective invariants. Knowing the inheritance of the invariants of projective geometry, the aim was the mathematical generalization of the integrated model and the creation of a projective relationship between the reference surfaces of conical and cylindrical spiral surfaces. As a result, the improved constructive geometric model was created, in which the method of analytically creating the projective geometric relationship between the reference surfaces of conical and cylindrical helicoid surfaces has been described for the first time in this article. This procedure is considered the most important result of the present article. Another significance of the further development presented is that during production of the conical helicoid surface, the thread pitch fluctuation has been eliminated. The results obtained, consisting of an improved geometric model, lead to a new geometry of the technological environment regarding the relative position of the cutting tool and the workpiece as well as the relative motion between them.

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Manufacturing Method for Large Cylindrical Worm Gear Set of ISO Type I on Universal CNC Machine Tools

Cited by 3 publications

References 40 publications

Challenges of Engineering Applications of Descriptive Geometry

Challenges of Engineering Applications of Descriptive Geometry

Research Progress on the Manufacturing of Screw-Shaped Parts in Screw Compressors

Generalization Process of the Integrated Mathematical Model Created for the Development of the Production Geometry of Complicated Surfaces

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