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Research Papers

Design Method of Double Ball Artifact for Use in Evaluating the Accuracy of a Gear-Measuring Instrument

[+] Author and Article Information
Masaharu Komori1

Department of Mechanical Engineering and Science, Kyoto University, Yoshidahonmachi, Sakyo-ku, Kyoto-shi, Kyoto 606-8501, Japankomorim@me.kyoto-u.ac.jp

Fumi Takeoka, Aizoh Kubo

Department of Mechanical Engineering and Science, Kyoto University, Yoshidahonmachi, Sakyo-ku, Kyoto-shi, Kyoto 606-8501, Japan

Koshi Kondo

Dimensional Standards Section, National Metrology Institute of Japan, AIST, Tsukuba, Ibaraki 305-8563, Japansonko.osawa@aist.go.jp

Yohan Kondo

Department of Mechanical and Environmental Informatics, Tokyo Institute of Technology, Ookayama 2-12-1, Meguro-ku, Tokyo 152-8550, Japankondou.y@aist.go.jp

Toshiyuki Takatsuji, Sonko Osawa

Dimensional Standards Section, National Metrology Institute of Japan, AIST, Tsukuba, Ibaraki 305-8563, Japan

1

Corresponding author.

J. Mech. Des 132(7), 071010 (Jul 07, 2010) (10 pages) doi:10.1115/1.4001875 History: Received July 14, 2009; Revised May 06, 2010; Published July 07, 2010; Online July 07, 2010

Vibration of gears is a serious problem in mechanical devices. The characteristics of these vibrations are strongly affected by tooth flank form deviation of micrometer or submicrometer order. The quality of manufactured gears is controlled by a gear-measuring instrument. The accuracy of the profile measurement by such an instrument is evaluated using a master gear or an involute artifact. However, it is difficult to manufacture gears with high accuracy because the involute is a complicated geometrical form. To solve this problem, the double ball artifact (DBA) has been proposed as a means to evaluate the profile measurement accuracy. The application of the DBA requires a DBA design method so that the DBA can be applied to a wide variety of gear dimensions in the industrial field and can realize high-precision evaluation. In the present study, a design method is proposed for the DBA, and the dimensions, tolerance, and material of the DBA are determined. A DBA is designed and manufactured according to the proposed design method and the effectiveness of the manufactured DBA is verified experimentally using a gear-measuring instrument.

Copyright © 2010 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Double ball artifact

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Figure 2

Contact condition between the form checking ball of the DBA and the stylus tip of the probe of the gear-measuring instrument: (a) definitions of points and (b) definitions of variables

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Figure 3

Example of a theoretical measurement curve

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Figure 4

Setting and adjustment of the posture and position of the DBA before profile measurement: (a) adjustment of the posture of the DBA and (b) adjustment of the position of the DBA

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Figure 5

Design parameters of the DBA

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Figure 6

Effect of distance between balls on the theoretical measurement curve

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Figure 7

Characteristics of the optimal distance between balls and its effect on the evaluation range: (a) optimal distance rdopt between the balls and (b) evaluation range of rotational angle under rdopt

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Figure 8

Variation in the theoretical measurement curve with form checking ball radius, where the distance between the balls is optimal rdopt

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Figure 9

Deviation at peaks 1 and 2 and at valley V of the theoretical measurement curve, where the distance between the balls is optimal rdopt

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Figure 10

Effect of a 1°C temperature increase on the difference curve between the theoretical measurement curve and the measurement curve affected by the error in rd of the DBA due to thermal expansion

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Figure 11

Structure to fix the ball to the base plate using a spring

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Figure 12

Forces applied to the ball during measurement

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Figure 13

Test device used to investigate the adhesive limitation of epoxy resin between the ball and the shaft: (a) structure of the test device and (b) photograph of the test device

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Figure 14

Variation in the theoretical measurement curve with respect to the distance between balls

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Figure 15

Examples of posture error of the DBA

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Figure 16

Difference between the theoretical measurement curves with and without tilting error

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Figure 17

Flowchart of the DBA design method

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Figure 18

Schematic diagram of the proposed DBA

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Figure 19

Schematic diagram of the base plate hole and the ball and shaft assembly

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Figure 20

Manufactured DBA

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Figure 21

Photographs of the measurement of DBA using the gear-measuring instrument: (a) gear-measuring instrument and (b) close-up of the probe

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Figure 22

Comparison of the actual measurement curve obtained using the gear-measuring instrument and the theoretical measurement curve: (a) actual measurement curve and theoretical curve and (b) difference curve

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