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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%.
Alongside the macro test parameters on tooth flanks for profile and tooth traces, surface properties (roughness) play a decisive role in ensuring proper toothed gear function. This article addresses roughness measurement systems on tooth flanks. In addition to universal test equipment, modified test equipment based on the profile method for use on gears is addressed in particular. The equipment application here refers to cylindrical gear flanks and bevel gear flanks. The most important roughness parameters, as well as the implementation of the precise measurement procedure will also be described under consideration of the applicable DIN EN ISO standards as well as the current VDI/VDE Directive 2612 Sheet 5.
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.
Most research on micropitting is done on small-sized gears. This article examines whether those results are also applicable to larger gears.
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.
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 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.
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?
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.
A reader asks about ion-nitride finished shafts and the proper friction coefficient to be used for calculations.
Grinding of bevel and hypoid gears creates on the surface a roughness structure with lines that are parallel to the root. Imperfections of those lines often repeat on preceding teeth, leading to a magnification of the amplitudes above the tooth mesh frequency and their higher harmonics. This phenomenon is known in grinding and has led in many cylindrical gear applications to an additional finishing operation (honing). Until now, in bevel and hypoid gear grinding, a short time lapping of pinion and gear after the grinding operation, is the only possibility to change the surface structure from the strongly root line oriented roughness lines to a diffuse structure.
Load-carrying capacity of gears, especially the surface durability, is influenced by their tooth surface roughness in addition to their tooth profiles and tooth traces.
The phenomena of deterioration of surfaces are generally very complex and depend on numerous conditions which include the operating conditions, the type of load applied, the relative speeds of surfaces in contact, the temperature, lubrication, surfaces hardness and roughness, and the compatibility and nature of materials.
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.
Inspection of the cutting blades is an important step in the bevel gear manufacture. The proper blade geometry ensures that the desired gear tooth form can be achieved. The accuracy of the process can be compromised when the blade profile consists of several small sections such as protuberance, main profile, top relief and edge radius. Another common obstacle - are outliers which can be caused by dust particles, surface roughness and also floor vibrations during the data acquisition. This paper proposes the methods to improve the robustness of the inspection process in such cases.
News Items About roughness
1 Mahr Offers MahrSurf GD Series for Roughness Measurements (April 3, 2019)
Mahr Inc. has announced the addition of the MarSurf GD series for roughness measurements to its new line of surface measuring instruments... Read News
2 Mitutoyo Releases Portable Surface Roughness Tester (June 20, 2012)
Mitutoyo America Corporation announces availability of the new Surftest SJ-411/412 portable surface roughness tester. The SJ-411/412 prov... Read News