Effects of Different Hard Finishing Processes on Gear Excitation

Maximilian Trübswetter,Joshua Götz,Michael Otto,Bernhard Kohn,Karsten Stahl

doi:10.3390/machines9080169

Abstract

Gearboxes are essential in mechanical drive trains for power transmission. A low noise emission and thus an optimized excitation behavior is a substantial design objective for many applications in terms of comfort and operational safety. There exist numerous processes for manufacturing gears, which all show different properties in relation to the process variables and, therefore, differences in the resulting accuracy and quality of the gear flank. In this paper, the influence of three different manufacturing processes for hard finishing—continuous generating grinding, polish grinding and gear skiving—on the surface structure of gear flanks and the excitation behavior is investigated experimentally and analyzed by the application force level. A tactile scanning of the gear flanks determines the flank surface structure and the deviations from the desired geometry. A torsional acceleration measurement during speed ramp-ups at different load levels is used to analyze the excitation of the gears. The results show only a minor influence of the surface structure on the application force level. The excitation behavior is dominated by the influence of the flank modification and its deviation from the design values.

Highlights

IntroductionFor the efficient operation of a gear pair, the quality, geometrical accuracy and the shape of the gear tooth profile is essential
The Ra-values of the gears manufactured by continuous generating grinding and polish grinding are below the mean roughness values stated by [4]
The geometrical accuracy and the quality of the gear flank form is essential for the operation of a gear stage with respect to load capacity, efficiency and excitation

Summary

Introduction

For the efficient operation of a gear pair, the quality, geometrical accuracy and the shape of the gear tooth profile is essential. In regard to the performance of gears the surface structure of a gear flank is crucial. The flank microstructure influences power losses, load-carrying capacities and the noise behavior of gears. Clearly visible structures, e.g., feeding marks, may have an impact on excitation behavior. The different manufacturing processes affect gear noise differently [1]

Methods

Discussion

Conclusion