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The method of cutting teeth on a cylindrical gear by the hobbing process has been in existence since the late 1800s. Advances have been made over the years in both the machines and the cutting tools used in the process. This paper will examine hob tool life and the many variables that affect it. The paper will cover the state-of-the-art cutting tool materials and coatings, hob tool design characteristics, process speeds and feeds, hob shifting strategies, wear characteristics, etc. The paper will also discuss the use of a common denominator method for evaluating hob tool life in terms of meters (or inches) per hob tooth as an alternative to tool life expressed in parts per sharpening.
I have a query (regarding) calculated gear life values. I would like to understand for what % of gear failures the calculated life is valid? Is it 1-in-100 (1% failure, 99% reliability) or 1-in-one-thousand (0.1% failure)?
How dynamic load affects the pitting fatigue life of external spur gears was predicted by using NASA computer program TELSGE. TELSGE was modified to include an improved gear tooth stiffness model, a stiffness-dynamic load iteration scheme and a pitting-fatigue-life prediction analysis for a gear mesh. The analysis used the NASA gear life model developed by Coy, methods of probability and statistics and gear tooth dynamic loads to predict life. In general, gear life predictions based on dynamic loads differed significantly from those based on static loads, with the predictions being strongly influenced by the maximum dynamic load during contact.
If a gear system is run continuously for long periods of timeâ€”or if the starting loads are very low and within the normal operating spectrumâ€”the effect of the start-up conditions may often be insignificant in the determination of the life of the gear system. Conversely, if the starting load is significantly higher than any of the normal operating conditions, and the gear system is started and stopped frequently, the start-up load may, depending on its magnitude and frequency, actually be the overriding, limiting design condition.
This article presents some of the findings of cutting investigations at WZL in which the correlation of cutting parameters, cutting materials, tool geometry and tool life have been determined.
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.
Spur gear endurance tests were conducted to investigate the surface pitting fatigue life of noninvolute gears with low numbers of teeth and low contact ratios for the use in advanced application. The results were compared with those for a standard involute design with a low number of teeth. The gear pitch diameter was 8.89 cm (3.50 in.) with 12 teeth on both gear designs. Test conditions were an oil inlet temperature of 320 K (116 degrees F), a maximum Hertz stress of 1.49 GPa (216 ksi), and a speed of 10,000 rpm. The following results were obtained: The noninvolute gear had a surface pitting fatigue life approximately 1.6 times that of the standard involute gear of a similar design. The surface pitting fatigue life of the 3.43-pitch AISI 8620 noninvolute gear was approximately equal to the surface pitting fatigue life of an 8-pitch, 28-tooth AISI 9310 gear at the same load, but at a considerably higher maximum Hertz stress.
Designing and sizing a rack-and-pinion system, per AGMA and ISO gear calculation.
As is well known in involute gearing, â€śperfectâ€ť involute gears never work perfectly in the real world. Flank modifications are often made to overcome the influences of errors coming from manufacturing and assembly processes as well as deflections of the system. The same discipline applies to hypoid gears.
A discussion of ISO and AGMA standards for gears, shafts and bearings, and the art of designing a gearbox that meets your requirements.
In this paper, the potential for geometrical cutting simulations - via penetration calculation to analyze and predict tool wear as well as to prolong tool life - is shown by means of gear finish hobbing. Typical profile angle deviations that occur with increasing tool wear are discussed. Finally, an approach is presented here to attain improved profile accuracy over the whole tool life of the finishing hob.
The search for greater gear life involves improvement in cost, weight and increased power output. There are many events that affect gear life, and this paper addresses those relating to fatigue, gear tooth pitting, fatigue strength losses due to the heat treating processes and shot peening technique. The capability of shot peening to increase fatigue strength and surface fatigue life eliminate machine marks which cause stress risers, and to aid in lubrication when properly controlled, suggests increased use and acceptance of the process.
Accurate prediction of gear dynamic factors (also known as Kv factors) is necessary to be able to predict the fatigue life of gears. Standards-based calculations of gear dynamic factors have some limitations. In this paper we use a multibody dynamic model, with all 6 degrees of freedom (DOF) of a high-speed gearbox to calculate gear dynamic factors. The findings from this paper will help engineers to understand numerous factors that influence the prediction of dynamic factors and will help them to design more reliable gears.
One of the major problems of plastic gear design is the knowledge of their running temperature. Of special interest is the bulk temperature of the tooth to predict the fatigue life, and the peak temperature on the surface of the tooth to avert surface failure. This paper presents the results of an experimental method that uses an infrared radiometer to measure the temperature variation along the profile of a plastic gear tooth in operation. Measurements are made on 5.08, 3.17, 2.54, 2.12 mm module hob cut gears made from nylon 6-6, acetal and UHMWPE (Ultra High Molecular Weight Polyethylene). All the tests are made on a four square testing rig with thermoplastic/steel gear pairs where the plastic gear is the driver. Maximum temperature prediction curves obtained through statistical analysis of the results are presented and compared to data available from literature.
Planetary gear transmissions are compact, high-power speed reducers that use parallel load paths. The range of possible reduction ratios is bounded from below and above by limits on the relative size of the planet gears. For a single-plane transmission, the planet gear has no size of the sun and ring. Which ratio is best for a planetary reduction can be resolved by studying a series of optimal designs. In this series, each design is obtained by maximizing the service life for a planetary transmission with a fixed size, gear ratio, input speed, power and materials. The planetary gear reduction service life is modeled as a function of the two-parameter Weibull distributed service lives of the bearings and gears in the reduction. Planet bearing life strongly influences the optimal reduction lives, which point to an optimal planetary reduction ratio in the neighborhood of four to five.
This article summarizes the use of laboratory fatigue data for bearings and gears coupled with probabilistic life prediction and EHD theories to predict the life and reliability of a commercial turboprop gearbox.
Optimization is applied to the design of a spiral bevel gear reduction for maximum life at a given size. A modified feasible directions search algorithm permits a wide variety of inequality constraints and exact design requirements to be met with low sensitivity to initial values. Gear tooth bending strength and minimum contact ration under load are included in the active constraints. The optimal design of the spiral bevel gear reduction includes the selection of bearing and shaft proportions in addition to gear mesh parameters. System life is maximized subject to a fixed back-cone distance of the spiral bevel gear set for a specified speed ratio, shaft angle, input torque and power. Significant parameters in the design are the spiral angle, the pressure angle, the numbers of teeth on the pinion and gear and the location and size of the four support bearings. Interpolated polynomials expand the discrete bearing properties and proportions into continuous variables for gradient optimization. After finding the continuous optimum, a designer can analyze near-optimal designs for comparison and selection. Design examples show the influence of the bearing lives on the gear parameters in the optimal configurations. For a fixed back-cone distance, optimal designs with larger shaft angles have larger service lives.
In several applications like hoisting equipment and cranes, open gears are used to transmit power at rather low speeds (tangential velocity < 1m/s) with lubrication by grease. In consequence those applications have particularities in terms of lubricating conditions and friction involved, pairing of material between pinion and gear wheel, lubricant supply, loading cycles and behavior of materials with significant contact pressure due to lower number of cycles.
The Pentac Plus is the latest generation of Gleasonâ€™s Pentac bevel gear cutting system. It is designed to allow much higher tool life and improved productivity, especially for cutters using multiple face blade geometry.
Near-net gear forging today is producing longer life gears at significantly lower costs than traditional manufacturing techniques. Advances in forging equipment, controls and die-making capability have been combined to produce commercially viable near-net-shape gears in diameters up to 17" with minimum stock allowances. These forged gears require only minimal finishing to meet part tolerance specifications.
Most books related to the gear industry are more about the business side or the technical aspects of what we do.
Oliver E Saari was an engineer with two great professional loves in his life - writing and gear design, and he was devoted to each in their turn. The same original thinking that informed his fiction, giving life to tales of space exploration, the evolution of man, and many other topics, let him to become one of the great pioneers in gear design.
A common design goal for gears in helicopter or turboprop power transmission is reduced weight. To help meet this goal, some gear designs use thin rims. Rims that are too thin, however, may lead to bending fatigue problems and cracks. The most common methods of gear design and analysis are based on standards published by the American Gear Manufacturers Association. Included in the standards are rating formulas for gear tooth bending to prevent crack initiation (Ref. 1). These standards can include the effect of rim thickness on tooth bending fatigue (Ref 2.). The standards, however, do not indicate the crack propagation path or the remaining life once a crack has started. Fracture mechanics has developed into a useful discipline for predicting strength and life of cracked structures.
If only there were some source of endless knowledge, experience and wisdom to guide you through your gear-related problems. If only there were some philosopher on a mountaintop whose sole purpose was to bring enlightenment to your gear noise problems, to unravel the mysteries of profile shift, to provide insight to a critical gear manufacturing problem or to explain the meaning of life (gear life, that is).
Impact Technologies considers commercial version of software package.
Gears are designed to be manufactured, processed and used without failure throughout the design life of the gear. One of INFAC's objectives (*see p.24) is to help manufacture of gears to optimize performance and life. One way to achieve this is to identify failure mechanisms and then devise strategies to overcome them by modifying the manufacturing parameters.
The effect of the lubrication regime on gear performance has been recognized, qualitatively, for decades. Often the lubrication regime is characterized by the specific film thickness defined as the ratio of lubricant film thickness to the composite surface roughness. It can be difficult to combine results of studies to create a cohesive and comprehensive data set. In this work gear surface fatigue lives for a wide range of specific film values were studied using tests done with common rigs, speeds, lubricant temperatures, and test procedures.
Large marine gearboxes. More than a year in production, each weighing 125,000 pounds, the gearboxes were for U.S. Navy amphibious ships, for combining the power of 10,000 hp diesel engines to drive propeller shafts. They were also the last major gear products shipped from Philadelphia Gear Corp.â€™s King of Prussia factory.
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.
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
If you make hardened gears and have not seen any micropitting, then you havenâ€™t looked closely enough. Micropitting is one of the modes of failure that has more recently become of concern to gear designers and manufacturers. Micropitting in itself is not necessarily a problem, but it can lead to noise and sometimes other more serious forms of failure. Predicting when this will occur is the challenge facing designers.
Physical Vapor Deposited (PVD) coatings such as TiN (Titanium nitride) have been a boon for cutting tool manufacturers. They reduce wear and, therefore, extend tool life, which in turn reduces production costs. But PVD coatings are expensive, and when they fail, they cost both time and money, and they causes of the failure are not always readily apparent.
This article summarizes the development of an improved titanium nitride (TiN) recoating process, which has, when compared to conventional recoat methods, demonstrated tool life increases of up to three times in performance testing of hobs and shaper cutters. This new coating process, called Super TiN, surpasses the performance of standard TiN recoating for machining gear components. Super TiN incorporates stripping, surface preparation, smooth coating techniques and polishing before and after recoating. The combination of these improvements to the recoating process is the key to its performance.
High-speed machining using carbide has been used for some decades for milling and turning operations. The intermittent character of the gear cutting process has delayed the use of carbide tools in gear manufacturing. Carbide was found at first to be too brittle for interrupted cutting actions. In the meantime, however, a number of different carbide grades were developed. The first successful studies in carbide hobbing of cylindrical gears were completed during the mid-80s, but still did not lead to a breakthrough in the use of carbide cutting tools for gear production. Since the carbide was quite expensive and the tool life was too short, a TiN-coated, high-speed steel hob was more economical than an uncoated carbide hob.
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.
Richard Spens has been rebuilding antique machine tools for nearly a decade. He is drawn to the ornate architecture and fascinated by the open design that allows you to see inside a machine as it operates. "Working with machines has been a lifelong thing with me," said Spens, now a design engineer. "I started building steam engines when I was 10 years old." What he's working on now, however, is bigger than any steam engine or machine tool. In rural Livonia, Michigan, Spens is converting an old dairy barn into an accurate recreation of a turn-of-the-century, belt driven gear shop. It's an outgrowth of his interest in antique machine tools and, he feels, a way to stem the tide that is costing America so many manufacturing and skilled trade jobs.
The goal of gear drive design is to transit power and motion with constant angular velocity. Current trends in gear drive design require greater load carrying capacity and increased service life in smaller, quieter, more efficient gearboxes. Generally, these goals are met by specifying more accurate gears. This, combined with the availability of user-friendly CNC gear grinding equipment, has increased the use of ground gears.
Users of gear-cutting tools probably do not often consciously consider the raw material from which those hobs, broaches or shavers are made. However, a rudimentary awareness of the various grades and their properties may allow tool users to improve the performance or life of their tools, or to address tool failures. The high-speed steel from which the tool is made certainly is not the only factor affecting tool performance, but as the raw material, the steel may be the first place to start.
In recent years, the demands for load capacity and fatigue life of gears constantly increased while weight and volume had to be reduced. To achieve those aims, most of today's gear wheels are heat treated so tooth surfaces will have high wear resistance. As a consequence of heat treatment, distortion unavoidably occurs. With the high geometrical accuracy and quality required for gears, a hard machining process is needed that generates favorable properties on the tooth surfaces and the near-surface material with high reliability.
Traditionally, high-quality gears are cut to shape from forged blanks. Great accuracy can be obtained through shaving and grinding of tooth forms, enhancing the power capacity, life and quietness of geared power transmissions. In the 1950s, a process was developed for forging gears with teeth that requires little or no metal to be removed to achieve final geometry. The initial process development was undertaken in Germany for the manufacture of bevel gears for automobile differentials and was stimulated by the lack of available gear cutting equipment at that time. Later attention has turned to the forging of spur and helical gears, which are more difficult to form due to the radial disposition of their teeth compared with bevel gears. The main driver of these developments, in common with most component manufacturing, is cost. Forming gears rather than cutting them results in increased yield from raw material and also can increase productivity. Forging gears is therefore of greater advantage for large batch quantities, such as required by the automotive industry.
A high number of wind turbine gearboxes do not meet their expected design life, despite meeting the design criteria of current bearing, gear and wind turbine industry standards and certifications.
The lifetime of worm gears is usually delimited by the bronze-cast worm wheels. The following presents some optimized cast bronzes, which lead to a doubling of wear resistance.
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).
A large number of technologies aimed primarily at higher productivity were presented by exhibitors at the AMB, International Exhibition for Metal Working at the Stuttgart Trade Fair Centre in September. Following the successful 2010 show, AMB 2012 boasted further developments in energy and resource efficiency, higher productivity, life cycle performance, quality assurance and user-friendliness.
The hob is a perfect example of how a little manufacturing ingenuity can make a reliable, highly productive cutting tool. It's an engineering specimen that creates higher cutting speeds, better wear resistance and increases rigidity. The cutting tool alone, however, can't take all the credit for its resourcefulness. Advanced coating technology from companies like Sulzer, Oerlikon Balzers, Ionbond, Seco Tools and Cemecon helps improve cutting tools by reducing overall costs, increasing tool life and maintaining the highest levels of productivity. The following is a quick recap of new technologies and the latest information in the coating market.
Investment in advanced new manufacturing technologies is helping to reinvent production processes for bevel gear cutters and coarse-pitch hobs at Gleason - delivering significant benefits downstream to customers seeking shorter deliveries, longer tool life and better results.
The essence of designing gears is often by necessity risk-averse, given that many of them are used in applications where loss of life is a distinct possibility. The Gear Research Institute (GRI) at The Pennsylvania State University conducts risk reduction testing with the same goal in mind - whether it be gears in fighter jets, Ferris wheels, tanks, or countless other gear-reliant vehicles and machinery.
Environmentally friendly, highly efficient and lasting a product's lifetime. With characteristics like this, Pulsed-Plasma Diffusion (PPD) technology from Oerlikon Balzers has established itself as an industry standard for the treatment of large automotive press tooling. Now the technology specialists are targeting new applications with this advanced process, offering an alternative to traditional hard-chrome processes.
Recently, a new type of hob with carbide inserts has been introduced, providing higher cutting speeds, longer tool life and higher feed rates when compared to re-grindable, high-speed steel hobs. But with this kind of hob, new challenges occur due to positional errors of the cutting edges when mounted on the tool. These errors lead to manufacturing errors on the gear teeth which must be controlled. In this paper, the tooth quality of a gear manufactured by hobs with different quality classes is analyzed using a simulation model in combination with Monte Carlo methods.
A reader asks: While I have read a reasonable amount of the literature on the pros and cons of anti-wear and anti-scuff additives, I find that the more I read, the more confused I become. I could use some clarity in my life.
For maximum life in carburized and ground gearing, I have been advised that fully grinding a radius into the root gives maximum resistance against fatigue failures. Others have advised that a hobbed and unground radius root form is best. Which is best, and why?
Cracks initiated at the surface of case-hardened gears may lead to typical life-limiting fatigue failure modes such as pitting and tooth root breakage. Furthermore, the contact load on the flank surface induces stresses in greater material depth that may lead to crack initiation below the surface if the local material strength is exceeded. Over time the sub-surface crack propagation may lead to gear failure referred to as â€śtooth flank fractureâ€ť (also referred to as â€śtooth flank breakageâ€ť). This paper explains the mechanism of this subsurface fatigue failure mode and its decisive influence factors, and presents an overview of a newly developed calculation model.
your life and in your professional career is an inflection point for you to take stock of where you came from and where you are going.
If you've got a gear performance problem, the Gear Research Institute (GRI) is here to help you. Since inception in 1982, GRI has been a primarily industry sponsored, experimentation driven research facility. Whether establishing the fatigue life of gears or evaluating the impact of manufacturing processes on the performance of gears, GRI has pioneered methods and procedures for characterizing such properties that are accepted by the aerospace, vehicle and other industry sectors.
The diagnosis and prevention of gear tooth and bearing wear requires the discovery and understanding of the particular mechanism of wear, which in turn indicates the best method of prevention. Because a gearbox is a tribologically dependent mechanism, some understanding of gear and bearing tribology is essential for this process. Tribology is the general term for the study and practice of lubrication, friction and wear. If tribology is neglected or considered insignificant, poor reliability and short life will result.
Gears are toothed wheels used primarily to transmit motion and power between rotating shafts. Gearing is an assembly of two or more gears. The most durable of all mechanical drives, gearing can transmit high power at efficiencies approaching 0.99 and with long service life. As precision machine elements gears must be designed.
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.
Today it is common practice when climb hobbing to keep the direction of the hob thread the same as that of the helical gear. The same generalization holds true for the mass production of gears for automobiles. It is the authors' opinion, however, that conventional hobbing with a reverse-handed hob is more effective for the high-speed manufacture of comparatively small module gears for automobiles. The authors have proven both experimentally and theoretically that reverse-handed conventional hobbing, using a multi-thread hob with a smaller diameter is very effective for lengthening the life of the hob and for increasing cutting efficiency at high speeds.
In response to Ed Uberts letter, we have come a long way in gearing since WWII. The Europeans do use long addendum pinions in many cases. This modification does improve load capacity, sliding conditions and the working life of a gearset. When modifying a pinion tooth it is necessary to modify the gear tooth or adjust the center distance accordingly but we will leave that to the designers.
At its location in Roscoe, IL, the Forest City Gear facility is surrounded by wildlife splendor. Fruit trees, nature walks and the occasional cute and furry animal sighting create an unlikely landscape for a manufacturing site. Of course, cavorting with the cute and furry does have its drawbacks.
Gear designs are evolving at an ever accelerating rate, and gear manufacturers need to better understand how the choice of materials and heat treating methods can optimize mechanical properties, balance overall cost and extend service life.
The use of plastic gearing is increasing steadily in new products. This is due in part to the availability of recent design data. Fatigue stress of plastic gears as a function of diametral pitch, pressure angle, pitch line velocity, lubrication and life cycles are described based on test information. Design procedures for plastic gears are presented.
The gear tooth fillet is an area of maximum bending stress concentration. However, its profile is typically less specified in the gear drawing and hardly controlled during gear inspection in comparison with the gear tooth flanks. This paper presents a fillet profile optimization technique for gears with symmetric and asymmetric teeth based on FEA and a random search method. It allows achieving substantial bending stress reduction in comparison with traditionally designed gears. This bending stress reduction can be traded for higher load capacity, longer lifetime, lower noise and vibration and cost reduction.
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.
This paper shows an experimental study on the fatigue lifetime of high-heat polyamide (Stanyl) gears running in oil at 140Â°C. Based on previous works (Refs. 1â€“2), an analysis is made correcting for tooth bending and calculating actual root stresses. A comparison with tensile bar fatigue data for the same materials at 140Â°C shows that a good correlation exists between gear fatigue data and tensile bar fatigue data. This insight provides a solid basis for gear designers to design plastic gears using actual material data.
One of the most effective methods in solving the edge loading problem due to excess misalignment and deflection in aerospace actuation gearing is to localize tooth-bearing contact by crowning the teeth. Irrespective of the applied load, if the misalignment and/or deflection are large enough to cause the contact area to reduce to zero, the stress becomes large enough to cause failure. The edge loading could cause the teeth to break or pit, but too much crowning may also cause the teeth to pit due to concentrated loading. In this paper, a proposed method to localize the contact bearing area and calculate the contact stress with crowning is presented and demonstrated on some real-life examples in aerospace actuation systems.
In comparison with the traditional gear design approach based on preselected, typically standard generating rack parameters, the Direct Gear Design method provides certain advantages for custom high-performance gear drives that include: increased load capacity, efficiency and lifetime; reduced size, weight, noise, vibrations, cost, etc. However, manufacturing such directly designed gears requires not only custom tooling, but also customization of the gear measurement methodology. This paper presents definitions of main inspection dimensions and parameters for directly designed spur and helical, external and internal gears with symmetric and asymmetric teeth.
Gear shaving is a free-cutting gear finishing operation which removes small amounts of metal from the working surfaces of the gear teeth. Its purpose is to correct errors in index, helical angle, tooth profile and eccentricity. The process can also improve tooth surface finish and eliminate, by crowned tooth forms, the danger of tooth end load concentrations in service. Shaving provides for form modifications that reduce gear noise. These modifications can also increase the gear's load carrying capacity, its factor of safety and its service life.
When a gear set is to be designed for a new application, the minimum size gears with the required capacity are desired. These gears must be capable of meeting the power, speed, ratio, life, and reliability requirements.
The higher load carrying capacities, compact dimensions and longer life of hardened gears is an accepted fact in industry today. However, the costs involved in case hardening and subsequent finishing operations to achieve these advantages are considerable. For example, in order to achieve desired running properties on larger gears, it has been necessary to grind the tooth flanks. This costly operation can now be replaced, in many cases, by a new Hard Cutting (HC) process which permits the cutting of hardened gears while maintaining extremely low tooling costs.
Sometimes in the pressure to meet deadlines and handle the Crisis of the Day, we lose sight of the forest for the trees. As a partial cure for this syndrome, I recently reviewed the six interviews with gear industry leaders that have appeared in our pages during the last year, trying to get a grasp of a larger picture. It struck me with renewed force how six men, each with a lifetime of experience in this business, see the gear industry forest the same way.
Almost all machines or mechanical systems contain precision contact elements such as bearings, cams, rears, shafts, splines and rollers. These components have two important common requirements: first, they must possess sufficient mechanical properties, such as, high hardness, fatigue strength and wear resistance to maximize their performance and life; second, they must be finished to close dimensional tolerances to minimize noise, vibration and fatigue loading.
Primitive gears were known and used well over 2,000 years ago, and gears have taken their place as one of the basic machine mechanisms; yet, our knowledge and understanding of gearing principles is by no means complete. We see the development of faster and more reliable gear quality assessment and new, more productive manufacture of gears in higher materials hardness states. We have also seen improvement in gear applications and design, lubricants, coolants, finishes and noise and vibration control. All these advances push development in the direction of smaller, more compact applications, better material utilization and improved quietness, smoothness of operation and gear life. At the same time, we try to improve manufacturing cost-effectiveness, making use of highly repetitive and efficient gear manufacturing methods.
These lines, interesting enough, are from the notebooks of an artist whose images are part of the basic iconography of Western culture. Even people who have never set foot in a museum and wouldn't know a painting by Corregio from a sculpture by Calder, recognize the Mona Lisa. But Leonardo da Vinci was much more than an artist. He was also a man of science who worked in anatomy, botany, cartography, geology, mathematics, aeronautics, optics, mechanics, astronomy, hydraulics, sonics, civil engineering, weaponry and city planning. There was little in nature that did not interest Leonardo enough to at least make a sketch of it. Much of it became a matter of lifelong study. The breadth of his interests, knowledge, foresight, innovation and imagination is difficult to grasp.
Taxes may be one of the only two sure things in life, but that doesn't make them popular. Nobody is happy to pay them, and the bigger the amount due, the unhappier the taxpayer. Conversely, politicians know that coming out in favor of a tax cut is the equivalent of voting for apple pie and motherhood. It's a sure-fire success at the ballot box.
Traditional methods of manufacturing precision gears usually employ either hobbing or shaper cutting. Both of these processes rely upon generating the conjugate tooth form by moving the work-piece in a precise relation to the tool. Recently, attention has been given to forming gear teeth in a single step. Advantages to such a process include reduced production time, material savings, and improved performance characteristics. Drawbacks include complicated tool designs, non-uniformity of gears produced throughout the life of the tooling, and lengthy development times.
The following article is a collection of data intended to give the reader a general overview of information related to a relatively new subject within the gear cutting industry. Although carbide hobbing itself is not necessarily new, some of the methods and types of application are. While the subject content of this article may be quite broad, it should not be considered all-inclusive. The actual results obtained and the speeds, feeds, and tool life used in carbide hobbing applications can vary significantly.
The availability of technical software has grown rapidly in the last few years because of the proliferation of personal computers. It is rare to find an organization doing technical work that does not have some type of computer. For gear designers and manufacturers, proper use of the computer can mean the difference between meeting the competition or falling behind in today's business world. The right answers the first time are essential if cost-effective design and fabrication are to be realized. The computer is capable of optimizing a design by methods that are too laborious to undertake using hard calculations. As speeds continue to climb and more power per pound is required from gear systems, it no longer is possible to design "on the safe side" by using larger service factors. At high rotational speeds a larger gear set may well have less capacity because of dynamic effects. The gear engineer of today must consider the entire gear box or even the entire rotating system as his or her domain.
In the 1960's and early 1970's, considerable work was done to identify the various modes of damage that ended the lives of rolling element bearings. A simple summary of all the damage modes that could lead to failure is given in Table 1. In bearing applications that have insufficient or improper lubricant, or have contaminants (water, solid particles) or poor sealing, failure, such as excessive wear or vibration or corrosion, may occur, rather than contact fatigue. Usually other components in the overall system besides bearings also suffer. Over the years, builders of transmissions, axles, and gear boxes that comprise such systems have understood the need to improve the operating environment within such units, so that some system life improvements have taken place.
Durability is the most important criterion used to define the quality of a gear. The freezing of metals has been acknowledged for almost thirty years as an effective method for increasing durability, or "wear life," and decreasing residual stress in tool steels. The recent field of deep cryogenics (below -300 degrees F) has brought us high temperature superconductors, the superconducting super collider, cryo-biology, and magnotehydrodynamic drive systems. It has also brought many additional durability benefits to metals.
In this issue of Gear Technology, we are focusing on using computers to their greatest advantage in gear design and manufacturing. In a sense, that's old news. It's a cliche to suggest that computers make our work life easier and more productive. No company that wishes to remain competitive in today's global manufacturing environment can afford to be without computers in all their manifestations. We need them in the office; we need them next to our desks in place of drafting boards; we need them on the shop floor.
This issue of Gear Technology marks another milestone in the life of our magazine. After publishing 51 issues - nearly 200 articles containing close to 2,500 pages - we're ready to try something new.
Myth No. 1: Oil Is Oil. Using the wrong oil is a common cause of gear failure. Gears require lubricants blended specifically for the application. For example, slow-speed spur gears, high-speed helical gears, hypoid gears and worm gears all require different lubricants. Application parameters, such as operating speeds, transmitted loads, temperature extremes and contamination risks, must be considered when choosing an oil. Using the right oil can improve efficiency and extend gear life.
Gear designers face constant pressure to increase power density in their drivetrains. In the automotive industry, for example, typical engine torque has increased significantly over the last several decades. Meanwhile, the demands for greater fuel efficiency mean designers must accommodate these increased loads in a smaller, more lightweight package than ever before. In addition, electric and hybrid vehicles will feature fewer gears, with fewer transmission speeds, running at higher rpms, meaning the gears in those systems will have to endure life cycles far beyond what is typical with internal combustion engines.
News Items About life
1 Dillon Jaw Forming Ring Maximizes Jaw Life Through Uniform Grip (September 22, 2017)
The Dillon jaw forming ring is an easy-to-use tool that provides a more uniform grip on the workpiece, thereby maximizing jaw life for cu... Read News
2 SKFs New Cylindrical Roller Bearings Extend Wind Turbine Gearbox Life (April 11, 2006)
New SKF high-capacity cylindrical roller bearings for wind turbine gearboxes have been engineered to promote longer gearbox service life... Read News
3 Blaser Swisslube Fluid Designed for Long-Term Sump Life (February 6, 2008)
Blaser Swisslube, Inc., introduced BC 230, a liquid tool providing advanced stability and long-term sump life that improves machine uptim... Read News
4 Walter Cut Grooving Tool Delivers Improved Chip Control and Tool Life (August 25, 2015)
Walter recently introduced the Walter Cut G1011-P, a new grooving tool that can enhance surface quality, extend tool life, and improve pr... Read News
5 Coating Technology Extends Tool Life without Cutting Oil (April 2, 2009)
Mitsubishi Heavy Industries, Ltd. has developed a thin-film coating for applying to precision cutting tool surfaces to extend tool life a... Read News
6 PM Touches Your Life DVD Released (January 27, 2010)
Powder Metallurgy: The Preferred Metal-Forming Solution, a new video showcasing the fabrication capabilities of the various technologies ... Read News
7 Nortons New Gear Grinding Wheels Increase Life of Parallel Axis Spur Gears (April 11, 2006)
The new BRGg VPHS high speed grinding wheels from Saint Gobain are designed to reduce cycle times by increasing metal removal rates. The ... Read News
8 Former Boston Gear President Receives PTDA Lifetime Achievement Award (April 15, 2006)
Roger A. Pennycook, former president of Boston Gear and former vice president of Textron Fluid & Power Co., was the 17th recepient... Read News
9 Helix Wiper Geometries Reduce Vibrations and Increase Tool Life (February 13, 2008)
Seco Tools Inc. recently unveiled Helix wiper geometries for operations in high-feed machining of case hardened steels where standard wip... Read News
10 Irving Laskin Receives AGMA Lifetime Achievement Award (December 3, 2008)
Irving Laskin, a consultant in gear technology specializing in fine pitch gearing, received the AGMA Lifetime Achievement Award for his d... Read News
11 PowerCool MaxLife Coolants Give Biostability and Performance (March 30, 2010)
Rustlick PowerCool MaxLife and PowerCool MaxLife CF coolants are long-lasting water-soluble oils with new additives specifically formulat... Read News
12 Siemens Announces Lifelong Educational Advantage Program for Workforce Development in Secondary and Technical Schools (March 8, 2017)
Siemens announced the launch of a new workforce development program for secondary and technical schools across America called LEAP - the ... Read News
13 Iscar's Chatterfree End Mills Bring Longer Tool Life (July 20, 2011)
With a new level of built-in asymmetry, Iscar EC-H Chatterfree solid carbide endmills bring a new level of speed and process security to ... Read News
14 Emuge EF Series Drills Incorporate Special Geometry for Faster Penetration and Longer Tool Life (June 17, 2015)
Emuge Corp. recently announced the North American debut of its line of high-performance solid carbide drills. The new Emuge EF series dri... Read News
15 Cimcool Cimperial 861 Metalworking Fluid Increases Tool Life and Provides Superior Lubricity (July 13, 2015)
Cimcool recently announced the release of Cimperial 861 with InSol technology, a hybrid lubricity, semi-synthetic metalworking fluid, whi... Read News
16 Walter Parting Blade Adaptors Improve Tool Life (March 4, 2016)
Walter has introduced new parting blade adaptors for BMT/DO machines that ensure precision cooling of both the insert and the parting bla... Read News
17 Suhner Rego-Fix reCool Directly Applies Coolant-Lubricant Mix to Cutting Edge, Improves Tool Life (March 23, 2016)
Rego-Fix has launched a cost-effective and efficient attachment for the application of coolant-lubrication liquids through a tool based o... Read News
18 Pferd Polinox Non-Woven PNZ Finishing Drum Provides 25 Percent Longer Life than Standard Drums (June 10, 2016)
Pferd Inc. has announced a new linear finishing set for applications including rough stock removal, surface conditioning and consistent, ... Read News
19 Solar Atmospheres CEO Receives ASM Distinguished Life Membership Award (November 25, 2016)
William R. Jones, CEO of Solar Atmospheres, was presented with an ASM Distinguished Life Membership Award in October 2016 at ASM's an... Read News
20 Bill Bradley Awarded AGMAs Lifetime Achievement Award (April 3, 2006)
The AGMA Board of Directors awarded Bill Bradley, AGMAs Vice President for the Technical Division with the Lifetime Achievement Awa... Read News