Abstract
Small gears with high precision are necessary to satisfy the requirements in strength and noise of compact geared motors. Nicks are formed accidentally in the manufacturing process of gear and they have bad influences on the strength and noise of small gear. Therefore nicks must be removed in the final process of manufacturing. However it is difficult to remove nicks from surface-hardened small gears after heat treatment because the tooth groove of small gears is narrow. Therefore tool and method suitable for nick removal are necessary. In order to solve this problem, a gear-shaped tool composed of alumina-fiber-reinforced plastic (hereafter called ALFRP) and a removal method of nicks from small gears using it are proposed in this report. The manufacturing process of ALFRP gear-shaped tool is developed. ALFRP gear-shaped tool is rotated with a work gear and is oscillated in the axial direction in the proposed removal process. An experiment is carried out, in which the proposed removal method is applied to the surface-hardened gear by carburizing. The experimental result shows that the ALFRP gear-shaped tool and removal method are effective to remove nicks from surface-hardened gears.
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