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Bevel gears must be assembled in a specific way to ensure smooth running and optimum load distribution between gears. While it is certainly true that the "setting" or "laying out" of a pair of bevel gears is more complicated than laying out a pair of spur gears, it is also true that following the correct procedure can make the task much easier. You cannot install bevel gears in the same manner as spur and helical gears and expect them to behave and perform as well; to optimize the performance of any two bevel gears, the gears must be positioned together so that they run smoothly without binding and/or excessive backlash.
I would appreciate if you could assist with a gear failure (occurring) after just seven weeks in service, post installation. This driving gear wheel has been installed in a medium-speed engine with backlash present at four different positions; with additional backlash checked on the mating surfaces. All backlash was found within (OEM)-recommended values. Please note included photos — it seems that the crack has started at the root fillet. Any comments would be appreciated.
Multiple possibilities are available to increase the transmissible power of girth gears. These solutions include: using a larger module, increasing of the gear diameter through the number of teeth, enlarging the face width, and increasing the hardness of the base material. The first three parameters are mostly limited by cutting machine capability. Module, outside diameter, and face width (for a cast gear) can theoretically be increased to infinity, but not the cutting machine dimensions. There are also practical limits with respect to the installation of very large diameter/large face width gears.
This paper reviews the necessity for detailed specification, design and manufacture to achieve required performance in service. The precise definition of duty rating and a thorough understanding of the environmental conditions, whether it is in a marine or industrial application, is required to predict reliable performance of a gearbox through its service life. A case study relating to complex marine gears and other general practice is presented to review the techniques used by Allen Gears to design and develop a gearbox that integrates with the requirements of the whole machinery installation. Allen Gears has considerable experience in the design of a variety of industrial and marine gears(Ref. 1,2).
The quality of a gear and its performance is determined by the following five parameters, which should be specified for each gear: Pitch diameter, involute form, lead accuracy, spacing accuracy, and true axis of rotation. The first four parameters can be measured or charted and have to be within tolerance with respect to the fifth. Pitch diameter, involute, lead, and spacing of a gear can have master gear quality when measured or charted on a testing machine, but the gear might perform badly if the true axis of rotation after installation is no longer the same one used when testing the gear.
Advancements in machining and assembly techniques of thermoplastic gearing along with new design data has lead to increased useage of polymeric materials. information on state of the art methods in fabrication of plastic gearing is presented and the importance of a proper backlash allowance at installation is discussed. Under controlled conditions, cast nylon gears show 8-14 dBA. lower noise level than three other gear materials tested.
In 1985 a new tooling concept for high volume gear production was introduced to the gear manufacturing industry. Since then this tool, the wafer shaper cutter, has proven itself in scores of applications as a cost-effective, consistent producer of superior quality parts. This report examines the first high-production installation at the plant of a major automotive supplies, where a line of twenty shapers is producing timing chain sprockets.