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Research Papers

Computer-Aided Machine Setting for Lapping Optimization

[+] Author and Article Information
Qimi Jiang

Department of Mechanical Engineering, Laval University, Quebec City, QC, G1V 0A6, Canadaqimi_j@yahoo.com

Claude Gosselin

Department of Mechanical Engineering, Laval University, Quebec City, QC, G1V 0A6, Canadacgosselica@yahoo.ca

Jack Masseth

 American Axle and Manufacturing, 1840 Holbrook Avenue, Detroit, MI 48212jack.masseth@aam.com

J. Mech. Des 131(3), 031003 (Feb 02, 2009) (8 pages) doi:10.1115/1.3066548 History: Received September 19, 2007; Revised November 21, 2008; Published February 02, 2009

During hypoid gears lapping process, a gear set is running at varying operating positions and under a light load in order to lap the complete tooth surface. The pinions and gears are lapped in pairs. Hence, their tooth surfaces are not only cutters but also workpieces. In the contact region, the contact pressure and sliding speed are different from point to point. This makes lapping to be a very complicated abrasive wear process. So far, knowledge about the relationship between the removed materials and the lapping time as well as how to optimize the lapping process is quite limited. An algorithm was presented (Jiang, 2008, “Simulation of Hypoid Gear Lapping,” ASME J. Mech. Des., 130(11), p. 112601) to determine the wear coefficient k for the lapping process of hypoid gears. With the obtained wear coefficient k, a methodology for simulating the lapping process was proposed. Based on the wear coefficient obtained, this work presents a computer-aided machine setting procedure to optimize the lapping cycle in order to improve the lapping quality and efficiency.

FIGURES IN THIS ARTICLE
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Copyright © 2009 by American Society of Mechanical Engineers
Topics: Machinery , Grinding , Gears , Wear , Errors
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References

Figures

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Figure 1

Discretized contact region

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Figure 2

The contact pattern before lapping—gear IB tooth flank (using the error surface)

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Figure 3

Interpolation scheme for the contact pattern

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Figure 4

Error surface—pinion

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Figure 5

Error surface—gear

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Figure 6

Calculated contact patterns

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Figure 7

Calculated transmission errors

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Figure 8

Procedure for computer-aided lapping machine setting

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Figure 9

Effects of E and P on the center of contact

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Figure 10

Results obtained by the first set of optimized lapping machine settings in Table 1

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Figure 11

Results obtained by the second set of optimized lapping machine settings in Table 1

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Figure 12

Calculated results using CMM measurements after lapping

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Figure 13

Results obtained by the first set of optimized lapping machine settings in Table 2

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Figure 14

Results obtained by the second set of optimized lapping machine settings in Table 2

Tables

Errata

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