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The purpose of this article is to discuss ISO 4156/ANSI B92.2M-1980 and to compare it with other, older standards still in use. In our experience designing and manufacturing spline gauges and other spline measuring or holding devices for splined component manufacturers throughout the world, we are constantly surprised that so many standards have been produced covering what is quite a small subject. Many of the standards are international standards; others are company standards, which are usually based on international standards. Almost all have similarities; that is, they all deal with splines that have involute flanks of 30 degrees, 37.5 degrees or 45 degrees pressure angle and are for the most part flank-fitting or occasionally major-diameter-fitting.
Wave generators are located inside of flexsplines in most harmonic gear drive devices. Because the teeth on the wheel rim of the flexspline are distributed radially, there is a bigger stress concentration on the tooth root of the flexspline meshing with a circular spline, where a fatigue fracture is more likely to occur under the alternating force exerted by the wave generator. The authors' solution to this problem is to place the wave generator outside of the flexspline, which is a scheme named harmonic gear drive (HGD) with external wave generator (EWG).
A finite elements-based contact model is developed to predict load distribution along the spline joint interfaces; effects of spline misalignment are investigated along with intentional lead crowning of the contacting surfaces. The effects of manufacturing tooth indexing error on spline load distributions are demonstrated by using the proposed model.
News from the Gear Industry
Temperature Induced Dimensional Changes Temperature causes various materials to change size at different rate, known as their Coefficients of Expansion (COE). The effects of this phenomenon on precision dimensional measurements are continuous and costly to industry. Precautions can be taken to allow parts and gages to temperature stabilize before conducting gage R & R studies, but the fact remains that on the shop floor temperatures vary all the time. The slow pace at which industry has accepted this reality probably has to do with the subtlety of these tiny size variations and our inability to sense gradual, but significant temperature changes.
Introducing backlash into spline couplings has been common practice in order to provide for component eccentric and angular misalignment. The method presented here is believed to be exact for splines with even numbers of teeth and approximate for those with odd numbers of teeth. This method is based on the reduction of the maximum effective tooth thickness to achieve the necessary clearance. Other methods, such as tooth crowning, are also effective.
Engineering design requires many different types of gears and splines. Although these components are rather expensive, subject to direct wear, and difficult to replace, transmissions with gears and splines are required for two very simple reasons: 1) Motors have an unfavorable (disadvantageous) relation of torque to number of revolutions. 2)Power is usually required to be transmitted along a shaft.
Since the design of involute splines and their manufacture requires considerable knowledge, not only of the basic properties of the involute profile, but also of various other elements which affect the spline fit and the sometimes complex principles underlying manufacturing and checking equipment, the question is frequently raised as to why the involute profile is given preference in designing splines over the seemingly simpler straight sided tooth profile.
This article describes a new technique for the size determination of external Involute splines by using a span measuring method. It provides application performance information demonstrating how this method and its measurements correlate with the traditional spline ring gage sizing method.
Involute spline couplings are used to transmit torque from a shaft to a gear hub or other rotating component. External gear teeth on the shaft engage an equal number of internal teeth in the hub. Because multiple teeth engage simultaneously, they can transmit much larger torques than a simple key and keyway assembly. However, manufacturing variations affect the clearance between each pair of mating teeth, resulting in only partial engagement.
Industry News from October/November 1984 Gear Technology.