Conical Gear Research Articles

PERANCANGAN MODIFIKASI MESIN BENDING ROTARY BAJA APLIKASI STAND POT BUNGA

Plants grown in pots continue to grow year after year. A flower pot support or flower pot stand is required to add aesthetic value and save space. The purpose of this research is to develop a steel rotary bending machine design for flower pot stand applications The method used is to calculate the rotational speed of the bending mall, design the transmission, calculate the power and capacity of the machine, calculate and analyze the frame strength, and produce machine design results. The design produces a mall bending rotation of 4.5 rpm with diameters of 100 mm, 120 mm, and 150 mm, an electric motor with a rotation speed of 2840 rpm and a power of 1 HP, 4 pulleys and 2 types A V-belts, a shaft diameter of 20 mm and a 6 x 6 mm key, UCP and UCF type bearings, conical gears with a reduction of 10:16, a gearbox with a reduction of 1:40. The required power is 146 watt (0,2 horsepower), and the engine capacity is 243 bends per hour. The engine frame has dimensions of 750 x 550 x 1000 mm and is made of AISI 1045 material. The highest stress that occurs in the frame is 45.55 N/mm2.

Using abrasive flow finishing process to reduce noise and vibrations of cylindrical and conical gears

This paper reports on reduction of noise and vibrations of cylindrical and conical gears through simultaneous reduction in their microgeometry errors, functional parameters, and surface roughness by finishing them with abrasive flow finishing (AFF) process. Previously identified optimum values of AFF medium viscosity and finishing time were used during AFF of the chosen gears. Noise and vibrations characteristics of the unfinished gears and the AFF finished gears were studied by varying motor speed and applied load at four levels each. An indigenously developed test rig was used for spur and straight bevel gears whereas drivetrain diagnostic simulator was used for helical gears. Indigenously developed dual flank roll tester was used to evaluate functional parameters of the unfinished and the best finished gears by AFF process. It was found that AFF process simultaneously reduced microgeometry errors, functional parameters, maximum and average values of surface roughness of spur, helical, and straight bevel gears. It reduced noise and vibration by 5.2 dBA and 5.3 m/s2 for spur gears, by 3.4 dBA and 7.5 m/s2 for helical gears, and by 4.6 dBA and 4 m/s2 for straight bevel gears. This study proves that AFF is an easy-to-operate and effective process for reducing noise and vibrations of cylindrical and conical gears through simultaneous reduction in their microgeometry errors, functional parameters, and surface roughness values. Outcome of this work will be helpful for various manufactures and users of different types of gears.

A holistic approach for gear skiving design enabling tool load homogenization

Gear skiving is a highly productive manufacturing process for internal gears. Due to its challenging cutting conditions often insufficient tool life is achieved and localized wear occurs. There is a lack of tool parameters in process design that allow for an uniform and comparable characterization of the process kinematics and tool geometry. In this paper, a new method for calculating process kinematics and tool profile based on parameters of profile-shifted conical gears and an approach for tool load homogenization are presented. The high potential of the methods is demonstrated by comparative tool life tests with an improvement of 300%.

A Unified Theory for 3D Gear and Thread Metrology

We propose a unified theory for the metrological treatment of helical machine elements such as cylindrical and conical gears, worms, and screw threads. The main idea is to introduce a universal 3D geometry model for threaded components that provides for distinct parameterization using a unique set of geometry parameters and that offers and a functional description of the transverse profile. Using modern 3D coordinate measuring technology, a holistic evaluation algorithm yields the actual geometry as the result of a high dimensional best-fit procedure and form deviations as corresponding residuals. All determinants and evaluation parameters can then be calculated from the set of actual geometry parameters. By applying certain constraints to the model to be fitted, the novel method can be reduced to the established 2D methods and hence meets demands for the comparison of the two procedures. The results of the novel approach have proven to be very stable and they enable the evaluation of areal measurements with no loss of information.

The device which is suitable for simulating the working movement track of a kitchen water TAP

In this paper, a mechanical device is introduced, which changes the driving direction of the force through a conical gear, so as to achieve the goal of simulating the actual working state of the kitchen water TAP and improve the accuracy of detection.

Thermal Influence of the Tooth Geometry in Milling a Conical Gear

The thermal influence of the tooth geometry in a conical gear is considered for the case of milling by a cutting head. Formulas are derived for the maximum temperature and the temperature field in cutting as a function of the geometric parameters of the tooth. On that basis, research in a virtual environment corresponding to the actual conditions is possible at preproduction, and the thermal phenomena may be predicted as a function of the tooth geometry in the gear being milled.

Reconstitution of the geometric elements of a conic gear

Conical gears are used if the axes of the shafts between which the rotation movement is transmitted are concurrent. The technology of execution of these gears is more demanding, they are more sensitive to the deviations of execution and / or assembly and introduce large axial forces, which complicates, to some extent, the construction of the supports of the wheel support shafts. The straight-toothed conical gears, with relatively simple wheels for technological purposes, are used only at low peripheral speeds (𝑣 < 3 𝑚/𝑠), when step deviations and those of the tooth profiles do not yet produce high dynamic demands and noise. These gears, however, are sensitive to less precise mountings and to deformations, under load, of the support shafts. The calculation of the resistance of the conical gears, in contact and bending, is performed accepting the same calculation assumptions as in the calculation of cylindrical gears with straight teeth. It is, therefore, necessary to make a transition from the conical gear to an imaginary cylindrical gear, called virtual gear, and to find equivalence relations between the two gears - real and virtual.

Tooth surface fatigue strength analysis of hyper conical gear focusing on the internal crack growth

Tooth surface fatigue strength analysis of hyper conical gear focusing on the internal crack growth

Strength Analysis of Polymer Conical Gear Wheel Made with 3D Printing Technique

Abstract The article deals with the problem of designing conical gears with a curved line contour. The contour of the tooth flank is described by means of a helix and involutions. In the work, a conical gear designed to drive of the lower limb rehabilitation exoskeleton has analysed. Parameters of the conical gearbox have been adapted to design requirements of the exoskeleton. Gear wheels were made with ABS material using 3D printing technique. The article presents the results of strength calculations obtained using the method classical design of the gear wheals described in the norm ISO 6336-1996. In the strength calculations, bending and contact stresses were taken into account. Creating the contour of gears was aided through the gearbox wizard available in Inventor program. The work contains the results of a static tensile test of the material from which the gear wheels were made. In experimental and numerical studies, the orthotropy of the material used was taken into account. The orthogonal values of the Young’s modulus, the Poisson’s ratio and the Kirchhoff’s modulus were determined. The publication also includes partial results of fatigue tests in the area of normal stresses. In the research used to finite element method (FEM), determine of internal loads in the gear. A structure of the FEM model is described in detail. Maximum values of contact pressures determined by use to FEM models have been compared with the results obtained on the basis of Hertz’s formulas. The article presents basic geometrical and strength parameters of the designed gear. The work demonstrates the validity of the material models used. Limitations in the application of the classic method of calculating conical gears made of orthotropic materials have been indicated. The results of analytical and numerical calculations are presented in tabular and graphical form.

Constructiv and Technological Consideration on the Generation of Gear Made by the DLP 3D-Printed Methode

The aim of the work is conduct to highlight how the technological parameters has influence of 3D printed DLP on the generation of wheel, made from resin type material. In the first part of the paper is presents how to generate in terms of dimensional aspects specific design cylindrical gears, conical and worm gear. Generating elements intended to reduce the cost of manufacturing of these elements. Also are achieve the specific components of this work are put to test with a laboratory test stand which is presented in the paper in the third part of the paper. The tested gears generated by 3D-printed technique made with 3D printed with FDM or DLP technique. After the constructive aspects, proceed to the identification of conserved quantities, which have an impact both in terms of mechanical strength, but his cinematic, in order to achieve a product with kinematic features and good functional domain specific had in mind. The next part is carried out an analysis of the layers are generated using the DLP and FDM method using an optical microscope with magnification up to 500 times, specially adapted in order to achieve both visualization and measurement of specific elements. In the end part, it will highlight the main issues and the specific recommendations made to obtain such constructive mechanical elements.

Acoustic Analysis of Cylindrical, Conical and Worm Gears

The paper aims to determine the characteristic frequencies of an electric drill, by measuring and analyzing comparatively the variations of the acoustic intensity level, using the Fast Fourier Transform method (FFT). This was applied using a stand which had been specifically developed for the presented work. In two channel and multichannel systems, digital methods have been used for the calculation of cross properties as they were the only practical methods. Using digital techniques has gained considerable ground, being nowadays applied to problems once solved by resorting to analog methods. The increasing use of Fast Fourier Transform methods is found in single channel real time narrow band measurements and the Digital Filtering is replacing the Analog Filter bank which was used as the basis for real time analyzers operating with constant percentage bandwidth.

Determination of Tool Life in the Cutting of Conical Gears with Circular Teeth

The influence of the cutting conditions on the life of quadrilateral cutting heads in the rough cutting of conical gears with circular teeth is investigated experimentally.

Structure design and effects of conical gear roller on restraining rabbit ear defects during gear rolling

The gear rolling process using a conical gear roller was developed recently and has been proved to be feasible for forming cylindrical gears. However, the rabbit ear defect, which is normally present in the traditional rolling process, still exists. Therefore, an innovative structure for the conical gear roller is proposed to prevent rabbit ear defects. The size of the dedendum circle during the tooth forming stage is determined according to the height of the growing tooth on the blank at each moment, and the volume of the roller pressed into the blank is equivalent to that of the objective gear’s tooth space. Both simulations and experiments are carried out to investigate the effects of the revised rollers on the rolling process. The results show that the formation of the tooth profiles can be effectively confined to the desired volume cavity, so that there is no extra space for the formation of rabbit ears. The tooth is fully filled, and the rabbit ear defects are obviously reduced. The experimental results agree well with the numerical simulation. The present study can help in improving the integrity and accuracy of the formed teeth for the gear rolling process.

ВИКОРИСТАННЯ AUTODESK INVENTOR API ТА МОВИ ПРОГРАМУВАННЯ VISUAL BASIC ДЛЯ ОПРАЦЮВАННЯ ПАРАМЕТРІВ МОДЕЛІ (НА ПРИКЛАДІ ЗУБЧАСТИХ КОЛІС)

The consideration of the adaptation of the Autodesk Inventor package for the execution of drawings, in accordance with current standards was continued. The proposed changes relate to the development of gear models using the appropriate design wizard and the design of their drawings, in particular, the parameter table, according to standards. The created software application for the Autodesk Inventor package is described. It is implemented in the Visual Basic programming language, which provides access to the model database through the application programming interface (API). The choice of the specified programming environment is due to the fact that it is built-in to the Inventor package and has a powerful code debugger. The proposed module creates a number of additional user parameters for the gear model, which are transferred to the drawings made on the basis of the previously developed gear drawings template. This template contains the necessary tables for all variants of cylindrical and conical gears and was described in a previous article [6]. The problem of finding and selecting the necessary parameters from the database of the part has been solved, regardless of the mode of operation of the design wizard used (“component” or “element” modes). Also supported are the models obtained after creating gears with a valid involute tooth profile, obtained in the special mode of the gear generator. The launch of the proposed program is organized with the help of the created command button located on the tool ribbon of the “3D Model” tab. This application is introduced into the educational process and is recommended for industry, which will significantly speed up and simplify the work with the package. Keywords: computer modeling, parameterization, gears, software application, Inventor API, VBA.

Study on simulation for the tooth surface fatigue strength analysis of conical gear

Study on simulation for the tooth surface fatigue strength analysis of conical gear

To development of general theory of gearings synthesis on the basis of conical wheels formed by a tool of rack and disk type

Generalized scheme and special cases of schemes gears, which are synthesized on the basis of conical shaped blanks of cogwheels, formed by a tool of rack and disk type, are presented. The advantages of such gears in comparison with traditional cylindrical and conical gears first of all, layout advantages and ability to eliminate backlash in the gearing both at manufacturing stage and at stage of operation of designed mechanisms are described. The main hypothesis used in the development of general theory of synthesis of gears under consideration involved is formulated. The notion of a general type initial link is given and essence of synthesis of gears in generalizing coordinates is disclosed, which allows to maximally reveal geometric-kinematic possibilities of gearing. The main provisions of general theory of synthesis of considered gears in a limiting area existence of gearing by means of a change in the shape and coordinates of points local areas, corresponding to one or another set of qualitative indicators are formulated.

Investigation on gear rolling process using conical gear rollers and design method of the conical gear roller

A type of gear rolling process using conical gear rollers was firstly proposed in this study. Different with the cylindrical gear rollers used in the traditional gear rolling process, the roller which looks like a conical gear with different tooth profile along the axial direction was adopted in the rolling process. Besides, the radial feed applied on the roller in traditional rolling process was replaced by the axial feed applied on the blank. The proposed rolling process was divided into three stages, viz., tooth graduation, tooth forming and tooth finishing. According to the function of the roller in each stage, the structure of the conical gear roller was designed. Importantly, the detailed formulas to calculate the essential parameters of the gear roller’s tooth in tooth forming stage were established, such as the diameter of addendum circle, the radius of addendum tip, the pressure angle, and the cone angle. Through the numerical simulation, the variation and forming mechanism of the tooth profile at different stages were analyzed. The results revealed that the proposed process achieves better uniform tooth graduation and refining of the tooth profile, which increase the forming accuracy of the tooth to some extent in rolling process. Moreover, the experimental device was developed and the feasibility of the conical gear rolling process was verified.

Capabilities evaluation of WSEM, milling and hobbing for meso-gear manufacturing

ABSTRACTThis paper describes manufacturing capabilities evaluation of wire spark erosion machining (WSEM), milling and hobbing to manufacture meso straight bevel gear (MSBG) and meso helical gear (MHG) made of SS 304 using microgeometry, macrogeometry, flank surface topology, surface finish, microstructure, microhardness, manufacturing time and cost, and gear material loss. Experiments were conducted using the parameters of WSEM, milling and hobbing processes optimized through trial experiments. This study reveals that WSEM manufactured MSBG and MHG possess better microgeometry (DIN 5-7), macrogeometry (29, 33, and 46 µm deviation in span, tooth thickness and outside diameter for MHG), topology, higher microhardness, superior microstructure, lower manufacturing time (25 and 20 min, respectively) and cost ($ 4 for both), smaller loss of gear material but poor surface finish (1.07 and 6.60 µm as average and maximum surface roughness for MHG and 1.04 and 6.16 µm for MSBG) than milled MSBG and hobbed MHG. Microstructure study showed presence of burrs and marks of the cutting tool on the flanks of the best quality hobbed MHG and milled MSBG. It proves that WSEM is a superior, economical, material efficient, and environment friendly process to manufacture meso-sized cylindrical and conical gears of higher accuracy and better quality with excellent repeatability.

A GENERALIZED METHOD FOR PREDICTING CONTACT STRENGTH, WEAR, AND THE LIFE OF INVOLUTE CONICAL SPUR AND HELICAL GEARS: PART 1. SPUR GEARS

The paper presents the results of research undertaken to determine maximum contact pressures, wear, and the life of involute conical spur gear, taking into account gear height correction, tooth engagement, and weargenerated changes in the curvature of their involute profile. Moreover, we have established the following: (a) the initial contact pressures are higher in the internal section with double-single-double tooth engagement; (b) the highest values can be observed at the entry of single tooth engagement; (c) the maximal tooth wear of the wheels in the frontal section will be less than half of that in the internal section; (d) profile shift coefficients have an optimum at which the highest gear life is possible; and (e) gear life in the internal section will be less than half of that the frontal section. The calculations were made for a reduced cylindrical gear using a method developed by the authors. The effect of applied conditions of tooth engagement in the frontal and internal sections of a cylindrical gear ring is shown graphically. In addition, optimal correction coefficients ensuring the longest possible gear life are determined.

A GENERALIZED METHOD FOR PREDICTING CONTACT STRENGTH, WEAR, AND THE LIFE OF INVOLUTE CONICAL SPUR AND HELICAL GEARS: PART 2. HELICAL GEARS

The paper presents the results of research undertaken to determine maximum contact pressures, wear, and the life of involute conical helical gear, taking account of gear height correction, tooth engagement, and weargenerated changes in the curvature of their involute profile. We have established the following: (a) initial maximal contact pressures will be almost the same at the engagement in external and internal segments; (b) their highest meanings occur in different points of engagement depending on the coefficients of displacement; (c) the maximal tooth wear of the rings in the internal section will be a little bit lower than in the external; (d) the coefficients of displacement have an optimum at which the highest gear life is possible; and, (e) the gear life in the frontal section will be 1.25 lower than in the internal section. The calculations were made for a reduced cylindrical gear using a method developed by the authors. The effect of applied conditions of tooth engagement in the frontal and internal sections of a cylindrical gear ring is shown graphically. In addition, optimal correction coefficients ensuring the longest possible gear life are determined.