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This article shows the newest developments to reduce overall cycle time in grinding wind power gears, including the use of both profile grinding and threaded wheel grinding.
The GS:TE-LM thread grinder from Drake Manufacturing is fitted with a robot load/unload system that provides maximum throughput for high-volume production of ground threads.
Modern gearboxes are characterized by high torque load demands, low running noise and compact design. In order to fulfill these demands, profile and lead modifications are being applied more often than in the past. This paper will focus on how to produce profile and lead modifications by using the two most common grinding processesâ€”threaded wheel and profile grinding. In addition, more difficult modificationsâ€”such as defined flank twist or topological flank correctionsâ€”will also be described in this paper.
Hard Gear Finishing (HGF), a relatively new technology, represents an advance in gear process engineering. The use of Computer Numerical Controlled (CNC) equipment ensures a high precision synchronous relationship between the tool spindle and the work spindle as well as other motions, thereby eliminating the need for gear trains. A hard gear finishing machine eliminates problems encountered in two conventional methods - gear shaving, which cannot completely correct gear errors in gear teeth, and gear rolling, which lacks the ability to remove stock and also drives the workpiece without a geared relationship to the master rolling gear. Such a machine provides greater accuracy, reducing the need for conventional gear crowning, which results in gears of greater face width than necessary.
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.
Grinding is a technique of finish-machining, utilizing an abrasive wheel. The rotating abrasive wheel, which id generally of special shape or form, when made to bear against a cylindrical shaped workpiece, under a set of specific geometrical relationships, will produce a precision spur or helical gear. In most instances the workpiece will already have gear teeth cut on it by a primary process, such as hobbing or shaping. There are essentially two techniques for grinding gears: form and generation. The basic principles of these techniques, with their advantages and disadvantages, are presented in this section.
Because of the better thermal conductivity of CBN abrasives compared to that of conventional aluminum oxide wheels, CBN grinding process, which induces residual compressive stresses into the component, and possibly improves the subsequent stress behavior. This thesis is the subject of much discussion. In particular, recent Japanese publications claim great advantages for the process with regard to an increased component load capacity, but do not provide further details regarding the technology, test procedures or components investigated. This situation needs clarification, and for the this reason the effect of the CBN grinding material on the wear behavior and tooth face load capacity of continuously generated ground gears was further investigated.
One process for hard finishing gears is generating gear grinding. Due to its high process efficiency, generating gear grinding has replaced other grinding processes such as profile grinding in batch production of small- and middle-sized gears. Yet despite the wide industrial application of generating gear grinding, the process design is based on experience along with time- and cost-intensive trials. The science-based analysis of generating gear grinding demands a high amount of time and effort, and only a few published scientific analyses exist. In this report a thermo-mechanical process model that describes influences on the surface zone in generating gear grinding is introduced.
An experimental validation of improvements possible with the latest threaded wheel grinding technology.
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.
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.
Shop floor inspection and gaging equipment is putting advanced metrology systems right on the factory floor. Hereâ€™s a collection of articles on shop floor inspection and gages from companies like Gleason, Mahr, Comtorgage, United Tool Supply and Frenco.