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Dutch design and Swiss ingenuity cause transmission breakthrough. Updated examples of Cylkro face gears in action.
There are three distinct gear types in angle drives. The most commonly used are bevel and worm drives. Face gear drives are the third alternative.
This article is part five of an eight-part series on the tribology aspects of angular gear drives. Each article will be presented first and exclusively by Gear Technology, but the entire series will be included in Dr. Stadtfeldâ€™s upcoming book on the subject, which is scheduled for release in 2011.
Bevel gears have been the standard for several decades in situations where power transmission has to occur between shafts mounted at a given angle. Now a new approach has been developed that challenges the bevel gear's de facto monopoly in such applications. The concept is based on the principle of the crown gear; i.e., a cylindrical pinion mates with a face gear. Crown Gear B.V. in Enschede, Holland, is the developer of these specialty gear teeth, which are marketed under the trade name Cylkro.
Designers are constantly searching for ways to reduce rotocraft drive system weight. Reduced weight can increase the payload, performance, or power density of current and future systems. One example of helicopter transmission weight reduction was initiated as part of the United States Army Advanced Rotocraft Transmission program. This example used a split-torque, face-gear configuration concept (Ref. 1). compared to a conventional design with spiral-bevel gears, the split-torque, face-gear design showed substantial weight savings benefits. Also, the use of face gears allows a wide-range of possible configurations with technical and economic benefits (Ref. 2).
Crown gearings are not a new type of gear system. On the contrary, they have been in use since very early times for various tasks. Their earliest form is that of the driving sprocket, found in ancient Roman watermills or Dutch windmills. The first principles of gear geometry and simple methods of production (shaper cutting) were developed in the 1940s. In the 1950s, however, crown gears' importance declined. Their tasks were, for example, taken over by bevel gears, which were easier to manufacture and could transmit greater power. Current subject literature accordingly contains very little information on crown gears, directed mainly to pointing out their limitations (Ref. 1).
Gear shaping is one of the most popular production choices in gear manufacturing. While the gear shaping process is really the most versatile of all the gear manufacturing methods and can cut a wide variety of gears, certain types of gears can only be cut by this process. These are gears closely adjacent to shoulders; gears adjacent to other gears, such as on countershafts; internal gears, either open or blind ended; crown or face gears; herringbone gears of the solid configuration of with a small center groove; rack; parts with filled-in spaces or teeth, such as are used in some clutches.
A study was performed to evaluate fault detection effectiveness as applied to gear-tooth pitting-fatigue damage. Vibration and oil-debris monitoring (ODM) data were gathered from 24 sets of spur pinion and face gears run during a previous endurance evaluation study.
Press quenching is designed to harden steel gears while minimizing distortion, and the process is especially applied for hardening large diameter thin-wall gears, face gears and bevel gears. The dimensional control aims at maintaining flatness, out-of-round, straightness and consistency of radial size. The press quench tooling and the process design have been mainly experience-based, using a trial and error approach for implementation of new processes, new gear materials and gear configurations.
In addition to the face milling system, the face hobbing process has been developed and widely employed by the gear industry. However, the mechanism of the face hobbing process is not well known.
The complete Product News section from the August 2018 issue of Gear Technology.
Manufacturing involute gears using form grinding or form milling wheels are beneficial to hobs in some special cases, such as small scale production and, the obvious, manufacture of internal gears. To manufacture involute gears correctly the form wheel must be purpose-designed, and in this paper the geometry of the form wheel is determined through inverse calculation. A mathematical model is presented where it is possible to determine the machined gear tooth surface in three dimensions, manufactured by this tool, taking the finite number of cutting edges into account. The model is validated by comparing calculated results with the observed results of a gear manufactured by an indexable insert milling cutter.
Could you explain to me the difference between spiral bevel gear process face hobbing-lapping, face milling-grinding and Klingelnberg HPG? Which one is better for noise, load capacity and quality?
The cutting process consists of either a roll only (only generating motion), a plunge only or a combination of plunging and rolling. The material removal and flank forming due to a pure generating motion is demonstrated in the simplified sketch in Figure 1 in four steps. In the start roll position (step 1), the cutter profile has not yet contacted the work. A rotation of the work around its axis (indicated by the rotation arrow) is coupled with a rotation of the cutter around the axis of the generating gear (indicated by the vertical arrow) and initiates a generating motion between the not-yet-existing tooth slot of the work and the cutter head (which symbolizes one tooth of the generating gear).
THE FINAL CHAPTER This is the last in the series of chapters excerpted from Dr. Hermann J. Stadtfeld's Gleason Bevel Gear Technology - a book written for specialists in planning, engineering, gear design and manufacturing. The work also addresses the technical information needs of researchers, scientists and students who deal with the theory and practice of bevel gears and other angular gear systems. While all of the above groups are of course of invaluable importance to the gear industry, it is surely the students who hold the key to its future. And with that knowledge it is reassuring to hear from Dr. Stadtfeld of the enthusiastic response he has received from younger readers of these chapter installments.
News about the latest products in the industry.
The latest technology on display in Columbus, OH. October 24-26.
A reader asks about ion-nitride finished shafts and the proper friction coefficient to be used for calculations.
The author compares the standard two-face blade technology with the three-face blade technology for manufacturing bevel gears.
"Documentation is not a Substitute for an Intuitive Interface." The author explores the development of modern controls for a CNC gear grinding machine.
In today's production environment, a variety of different measurement devices is used to assess the quality and accuracy of workpieces. These devices include CMMs, gear checkers, form testers, roughness testers, and more. It requires a high machine investment and a high handling effort - especially if a full end-of-line measurement is needed. One approach to reduce quality costs is to include all measurements in one single machine that is suitable and robust enough for use in production.
The complete Industry News section from the August 2018 issue of Gear Technology.
The face load factor is one of the most important items for a gear strength calculation. Current standards propose formulae for face load factor, but they are not always appropriate. AGMA 927 proposes a simpler and quicker algorithm that doesn't require a contact analysis calculation. This paper explains how this algorithm can be applied for gear rating procedures.
Chamfering and deburring have been described as "unloved," a "necessary evil" and, in fact - "dead." After all, manual deburring is still common in many shops.
The properties of both shot-peened and cold rolled PM gears are analyzed and compared. To quantify the effect of both manufacturing processes, the tooth root bending fatigue strength will be evaluated and compared to wrought gears.
The theory behind the latest bevel gear cutting tools is explained in detail.
Contrary to what appears to be popular belief, 5-axis CNC gear manufacturing is not limited to milling with end mill, ball mill or CoSIMT (Conical Side Milling Tool â€” it is the generic form of the Sandvik InvoMill and Gleason UpGear tools.) tools, where throughput is too low to prevent production at any significant level. Straight and spiral bevel gear manufacturing on 5-axis CNC machines using face mill cutters provides essentially the same throughput as conventional gear cutting machines â€” with added benefits.
Gear noise is among the issues of greatest concern in today's modern gearboxes. Significant research has resulted in the application of enhancements in all phases of gear manufacturing, and the work is ongoing. With the introduction of Electric Vehicles (EV), research and development in this area has surged in recent years. Most importantly, powerful new noise analysis solutions are fast becoming available.
Is a left-hand cutter required for a left-hand face mill part?
Spur cylindrical gears are usually cut using a hob and therefore present an essentially straight face to which crowning can be added to prevent edge contact. Rather than using a rack or hob, it is possible to cut cylindrical gears with a face mill cutter. In the following presentation, these gears are termed "spurved," i.e. â€” a contraction of "spur" and "curved."
Curved face width (CFW) spur gears are not popular in the gear industry. But these non-metallic gears have advantages over standard spur gears: higher contact ratio, higher tooth stiffness, and lower contact and bending stresses.
Superfinishing the working surfaces of gears and their root fillet regions results in performance benefits.
Non-uniform gear wear changes gear topology and affects the noise performance of a hypoid gear set. The aggregate results under certain vehicle driving conditions could potentially result in unacceptable vehicle noise performance in a short period of time. This paper presents the effects of gear surface parameters on gear wear and the measurement/testing methods used to quantify the flank wear in laboratory tests.
This presentation introduces a new procedure that - derived from exact calculations - aids in determining the parameters of the validation testing of spiral bevel and hypoid gears in single-reduction axles.
Heat treat suppliers look to the gear industry and the upcoming combined Gear Expo/Heat Treat 2013 for new business.
In earlier studies, surface roughness has been shown to have a significant influence on gear pitting life. This paper discusses how high surface roughness introduces a wear mechanism that delays the formation of pits. Accompanied by a full-page technical review.
The working surfaces of gear teeth are often the result of several machining operations. The surface texture imparted by the manufacturing process affects many of the gear's functional characteristics. To ensure proper operation of the final assembly, a gear's surface texture characteristics, such as waviness and roughness, can be evaluated with modern metrology instruments.
In a previous article, the authors identified two misconceptions surrounding gear superfinishing. Here, they tackle three more.
Bevel gear manufacturers live in one of two camps: the face hobbing/lapping camp, and the face milling/grinding camp.
This article is part four of an eight-part series on the tribology aspects of angular gear drives. Each article will be presented first and exclusively by Gear Technology, but the entire series will be included in Dr. Stadtfeldâ€™s upcoming book on the subject, which is scheduled for release in 2011.
In this paper a new method for the introduction of optimal modifications into gear tooth surfaces - based on the optimal corrections of the profile and diameter of the head cutter, and optimal variation of machine tool settings for pinion and gear finishingâ€”is presented. The goal of these tooth modifications is the achievement of a more favorable load distribution and reduced transmission error. The method is applied to face milled and face hobbed hypoid gears.
Most research on micropitting is done on small-sized gears. This article examines whether those results are also applicable to larger gears.
With the publishing of various ISO draft standards relating to gear rating procedures, there has been much discussion in technical papers concerning the various load modification factors. One of the most basic of parameters affecting the rating of gears, namely the endurance limit for either contact or bending stress, has not, however, attracted a great deal of attention.
Gear surface fatigue endurance tests were conducted on two groups of 10 gears each of carburized and hardened AlSI 9310 spur gears manufactured from the same heat of material
Spiral-bevel gears, found in many machine tools, automobile rear-axle drives, and helicopter transmissions, are important elements for transmitting power.
Rotary gear honing is a hard gear finishing process that was developed to improve the sound characteristics of hardened gears by: Removing nicks and burrs; improving surface finish; and making minor corrections in tooth irregularities caused by heat-treat distortion.
Spur gear surface endurance tests were conducted to investigate CBN ground AISI 9310 spur gears for use in aircraft applications, to determine their endurance characteristics and to compare the results with the endurance of standard vitreous ground AISI 9310 spur gears. Tests were conducted with VIM-VAR AISI 9210 carburized and hardened gears that were finish ground with either CBN or vitreous grinding methods. Test conditions were an inlet oil temperature of 320 K (116 degree F), an outlet oil temperature of 350 K (170 degree F), a maximum Hertz stress of 1.71 GPa (248 ksi), and a speed of 10,000 rpm. The CBN ground gears exhibited a surface fatigue life that was slightly better than the vitreous ground gears. The subsurface residual stress of the CBN ground gears was approximately the same as that for the standard vitreous ground gears for the CBN grinding method used.
Could the tip chamfer that manufacturing people usually use on the tips of gear teeth be the cause of vibration in the gear set? The set in question is spur, of 2.25 DP, with 20 degrees pressure angle. The pinion has 14 teeth and the mating gear, 63 teeth. The pinion turns at 535 rpm maximum. Could a chamfer a little over 1/64" cause a vibration problem?
Following is a report on the R&D findings regarding remediation of high-value, high-demand spiral bevel gears for the UHâ€“60 helicopter tail rotor drivetrain. As spiral bevel gears for the UHâ€“60 helicopter are in generally High-Demand due to the needs of new aircraft production and the overhaul and repair of aircraft returning from service, acquisition of new spiral bevel gears in support of R&D activities is very challenging. To compensate, an assessment was done of a then-emerging superfinishing method—i.e., the micromachining process (MPP)—as a potential repair technique for spiral bevel gears, as well as a way to enhance their performance and durability. The results are described in this paper.
Several trends in mechanical engineering are leading to greater surface stress on components and thus to unacceptable wear. These trends include greater stresses due to increased power densities; the need to maintain high precision of components throughout their service life; and the environmental imperative to reduce use of lubricants and additives.
Rotary gear honing is a crossed-axis, fine, hard finishing process that uses pressure and abrasive honing tools to remove material along the tooth flanks in order to improve the surface finish (.1-.3 um or 4-12u"Ra), to remove nicks and burrs and to change or correct the tooth geometry. Ultimately, the end results are quieter, stronger and longer lasting gears.
Surface roughness measuring of gear teeth can be a very frustrating experience. Measuring results often do not correlate with any functional characteristic, and many users think that they need not bother measuring surface roughness, since the teeth are burnished in operation. They mistakenly believe that the roughness disappears in a short amount of time. This is a myth! The surface indeed is shiny, but it still has considerable roughness. In fact, tests indicate that burnishing only reduces the initial roughness by approximately 25%.
In his Handbook of Gear Design (Ref.1), Dudley states (or understates): "The best gear people around the world are now coming to realize that metallurgical quality is just as important as geometric quality." Geometric accuracy without metallurgical integrity in any highly stressed gear or shaft would only result in wasted effort for all concerned - the gear designer, the manufacturer, and the customer - as the component's life cycle would be prematurely cut short. A carburized automotive gear or shaft with the wrong surface hardness, case depth or core hardness may not even complete its basic warranty period before failing totally at considerable expense and loss of prestige for the producer and the customer. The unexpected early failure of a large industrial gear or shaft in a coal mine or mill could result in lost production and income while the machine is down since replacement components may not be readily available. Fortunately, this scenario is not common. Most reputable gear and shaft manufacturers around the world would never neglect the metallurgical quality of their products.
Surface coatings or finishing processes are the future technologies for improving the load carrying capacity of case hardened gears. With the help of basic tests, the influence of different coatings and finishing processes on efficiency and resistance to wear, scuffing, micropitting, and macropitting is examined.
A very important parameter when designing a gear pair is the maximum surface contact stress that exists between two gear teeth in mesh, as it affects surface fatigue (namely, pitting and wear) along with gear mesh losses. A lot of attention has been targeted to the determination of the maximum contact stress between gear teeth in mesh, resulting in many "different" formulas. Moreover, each of those formulas is applicable to a particular class of gears (e.g., hypoid, worm, spiroid, spiral bevel, or cylindrical - spur and helical). More recently, FEM (the finite element method) has been introduced to evaluate the contact stress between gear teeth. Presented below is a single methodology for evaluating the maximum contact stress that exists between gear teeth in mesh. The approach is independent of the gear tooth geometry (involute or cycloid) and valid for any gear type (i.e., hypoid, worm, spiroid, bevel and cylindrical).
Face-milled hypoid pinions produced by the three-cut, Fixed Setting system - where roughing is done on one machine and finishing for the concave-OB and convex-IB tooth flanks is done on separate machines with different setups - are still in widespread use today.
Results from the Technical University of Munich were presented in a previous technical article (see Ref. 4). This paper presents the results of Ruhr University Bochum. Both research groups concluded that superfinishing is one of the most powerful technologies for significantly increasing the load-carrying capacity of gear flanks.
In the past, the blades of universal face hobbing cutters had to be resharpened on three faces. Those three faces formed the active part of the blade. In face hobbing, the effective cutting direction changes dramatically with respect to the shank of the blade. Depending on the individual ratio, it was found that optimal conditions for the chip removal action (side rake, side relief and hook angle) could just be established by adjusting all major parameters independently. This, in turn, results automatically in the need for the grinding or resharpening of the front face and the two relief surfaces in order to control side rake, hook angle and the relief and the relief angles of the cutting and clearance side.
Gear tooth wear and micropitting are very difficult phenomena to predict analytically. The failure mode of micropitting is closely correlated to the lambda ratio. Micropitting can be the limiting design parameter for long-term durability. Also, the failure mode of micropitting can progress to wear or macropitting, and then go on to manifest more severe failure modes, such as bending. The results of a gearbox test and manufacturing process development program will be presented to evaluate super-finishing and its impact on micropitting.
The traditional way of controlling the quality of hypoid gears' tooth flank form is to check the tooth flank contact patterns. But it is not easy to exactly judge the tooth flank form quality by the contact pattern. In recent years, it has become possible to accurately measure the tooth flank form of hypoid gears by the point-to-point measuring method and the scanning measuring method. But the uses of measured data of the tooth flank form for hypoid gears have not yet been well developed in comparison with cylindrical involute gears. In this paper, the tooth flank form measurement of generated face-milled gears, face-hobbed gears and formulate/generated gears are reported. The authors discuss the advantages and disadvantages of scanning and point-to-point measuring of 3-D tooth flank forms of hypoid gears and introduce some examples of uses of measured data for high-quality production and performance prediction.
News Items About face gears
1 AGMA Releases Publication on Face Gears (February 21, 2020)
The American Gear Manufacturers Association (AGMA) Technical Division is pleased to announce the publication of AGMA 916-A19, Face Gears ... Read News
2 KISSsoft Releases New Function for Face Gears (September 9, 2010)
A new functionality to generate a solid model of a face gear with arbitrary shaft angle and offset is implemented in the development vers... Read News