Papers by Keyword: Gear

Abstract: In this research we investigate geometric analysis and computer-aided modeling of wire bending machines. This focus on the traditional and modern approaches to their understanding shows how CAD modeling, 3D scanning, and surface roughness measurements are used to understand their mechanisms. Analysis of wire bending mechanics provides a comprehensive evaluation of manufacturing methods and their effect on performance. The results and methods of design provide a direction for future improvements to the design and functionality of these machines for optimized simultaneous manufacturing and operational performance.

Abstract: Over the past two decades, numerous research efforts have been aimed at developing efficient transmissions, in particular automotive ones, which can significantly reduce energy consumption and improve the dynamic properties of the car. The driving performance of a vehicle is one of the most important qualities that ensures comfortable movement of the passenger, which also affects traffic safety. One way to achieve this goal is to use transmissions that provide continuously variable control. gear ratio. The Continuously Variable Transmission (CVT) provides continuous shifting, changing the ratio between the input and output shafts within the desired range, which consequently improves fuel economy and vehicle performance by better matching engine operating conditions to changing road conditions. This article discusses the possibility of using composite transmissions - gear differential mechanisms closed by (CVT). Various schemes of composite transmissions are given. The conditions under which the transmission ratio of the entire transmission must be changed by changing the transmission ratio (CVT) included in the combined transmission have been studied.

Abstract: The requirements of gears are increasing rapidly in the global market for applications from micro electro mechanical systems (MEMS) to aerospace. Gears of various profiles and types including spiral-conical are used for motion as well as torque transfer in microsystems. The development of such gears is a challenging task because no compromise in their quality is acceptable. It necessitates highly accurate gear manufacturing process. This article presents such a process i.e. wire-assisted electrical discharge machining (WEDM) and development of stainless-steel made spiral-conical gears of miniature size. All minute aspects of spiral-conical gear development by WEDM are reported in this paper. In order to investigate the impact of process parameters and gear quality, an experimental study has been conducted based on Taguchi’s robust design of experiment technique. The developed gears are found with good manufacturing quality characteristics.

Abstract: The increasing demand for resource-efficient production methods is driving the development of new technologies. Sheet bulk metal forming (SBMF) offers the possibility to combine sheet metal and bulk forming operations. This allows the production of complex functional components with secondary forming elements from sheet metal. Compared to other production techniques such as machining, a more efficient use of material can be achieved. Further advantages are a near net shape production and increased strain hardening. SBMF processes are limited by forming technology boundaries. These include high forming forces, incomplete mould fillings and limited surface qualities. In this research, the possibility of enhancing the material flow, improving surface quality and reducing the tool loads in SBMF-processes is investigated by using a superimposed oscillation. The focus here is on achieving a high surface quality of components produced by forming technology and an enhanced material flow during forming. For this purpose, a forming process for ironing an axial gear geometry is superimposed with an oscillation in the main force flow.

Abstract: Industrial tomography is currently the fastest growing sector of non-destructive research. Until recently, the use of computed tomography in industry has been limited mostly to defects in materials due to lack of accuracy. Modern measuring machines combining metrology and tomography can extract information about the external geometry and volume of the part with high precision from a single scan. This article deals with the transmission gearing scanning, which is a functional component used in the mechanical transmission design. It is imperative that it does not contain internal defects that can largely render the transmission ineffective due to the strain caused by stress. The component is produced by Digital Light Processing (DLP) additive technology. The chosen production method ensures greater strength of the part. The part will be made of material call as „Proto GRY “on a FabPro1000 printer from the company 3D Systems, Inc. The production process of the model will depend on the change in the orientation of the part.

Abstract: This paper explains and demonstrates how miniature gears of excellent surface quality can be manufactured by modern machining methods. Necessity of gear finishing by post processes such as grinding, lapping, honing etc. is the major limitation of all conventional methods of miniature gear manufacturing. To overcome this limitation, modern machining methods such as wire-EDM, abrasive waterjet machining, and laser beam machining etc. have been explored. It resulted in significant achievements in geometric accuracy, surface finish, and integrity of miniature gears. Using modern machining methods, it is possible to manufacture gears equipped with precision finish (average roughness 1 μm), high geometric accuracy (DIN quality 5), and defect-free tooth surfaces at significantly low cost. This paper aims to facilitate researchers by providing information on important aspects as regards to the manufacturing of miniature gears by modern machining methods and hopes research and development in this area to establish the field further.

Abstract: Cold forging processes enable the economical production of high quality components like joints, shafts and gears. The manufactured parts are characterized by improved properties such as hardness, surface quality and fatigue strength. For manufacturing components using cold forging, a comprehensive knowledge regarding the cold forging procedure and its process parameters is needed. One important influencing factor, which needs to be analyzed to use the potential of this kind of processes, is the tribological system, especially the used lubricant. The tribological conditions significantly influence the material flow and thus the workpiece quality. Furthermore, resource efficient and environmentally benign metal forming processes became very important within the last decade. The present study evaluates the resulting tribological conditions and their differences for various cold forging lubricants with and without a zinc phosphate based lubricant carrier. The lubricants are based on molybdenum disulphide, polymers, or both inorganic salts and waxes. The tribological conditions of the different lubricants are investigated using the Double-Cup-Extrusion-Test (DCET) as a laboratory friction test.

Abstract: This report discusses how a transmission error curve is derived by a coordinate measuring machine, and the result by a coordinate measuring machine is compared with the result by a transmission error measuring machine. A vibration based on a gear pair engagement in fishing reel occurs when a handle of the reel rotates. When this vibration is large, an angler feels uncomfortable. In author’s previous reports, it is known that a rotational feeling depends on the transmission error curve. The result indicates that the rotational feeling can be improved if the accuracy of a tooth flank is improved. In order to reduce the transmission error, the error should be measured in high accuracy. In this research, a measurement method for evaluating the rotational feeling was reported using a face gear pair via a coordinate measuring machine and a transmission error measuring machine. As a result, it was confirmed that the result of measurement by the coordinate measuring machine agrees very well with the result of measurement by the transmission error measuring machine.

Abstract: This paper deals with hobbing and finish-hobbing that considers the machine environment when using various hard hob materials. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The results are summarized as follows. (1) Under the condition of hobbing with TiN-coated tools in dry cutting and with a minimal quantity of lubricant (MQL) system, P20 and P30 hob materials as the substrate show stable cutting and do not cause tool failure. The flank wear obtained with P30 is less than that obtained with P10 and P20 in the case of the coated TiAlN film tool. The MQL system shows flank wear reduction compared with dry cutting. (2) Under the condition of finish-hobbing, when using the TiN-coated tool, the flank wear obtained with dry cutting is smaller than that obtained with the MQL system. The flank wear increases in the order of P10, P20 and P30 hob materials, and the P10 hob material is effective. The TiAlN-coated P30 tool decreases flank wear and is suitable for finish-hobbing in dry cutting and with the MQL system. (3) Under the condition of hobbing, the finished surface roughness obtained with the MQL system when using TiN-and TiAlN-coated tools is smaller than that obtained by dry cutting. (4) Under the condition of finish-hobbing, the finished surface roughness obtained with TiN-and TiAlN-coated P30 is small in dry cutting and with the MQL system.

Abstract: This article presents the basis for and implementation of an approach to the development of the individualised gas carburization technology relying on optimisation of the process of carburizing surfaces of workpieces and taking into consideration working requirements. The approach is based on the hierarchical structure of carburization models, utilising the decomposition of global quality criteria and reflecting the relationship between the quality values of the hardened layer and the parameters of a technological impact on the workpiece. Taking the example of carburization of automobile gears, optimal parameters for the carburization technology are defined which minimise the duration of the process and maximise the precision of approximation to a given carbon distribution in the hardened layer within technical limitations.