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Technical Briefs

Tooth Contact Analysis and Manufacture on Multitasking Machine of Large-Sized Straight Bevel Gears With Equi-Depth Teeth

[+] Author and Article Information
Isamu Tsuji

Iwasa Tech Co., Ltd.,
62-4 Takase-cho, Funabashi-shi,
Chiba 273-0014, Japan
e-mail: tsuji-tech136@dream.jp

Kazumasa Kawasaki

Institute for Research Collaboration and Promotion,
Niigata University,
8050, Ikarashi 2-nocho,
Nishi-ku, Niigata 950-2181, Japan
e-mail: kawasaki@ccr.niigata-u.ac.jp

Hiroshi Gunbara

Department of Mechanical Engineering,
Matsue National College of Technology,
14-4, Nishi-ikuma-cho,
Matsue 690-8518, Japan
e-mail: gunbara@matsue-ct.jp

Haruo Houjoh

e-mail: hhoujoh@pi.titech.ac.jp

Shigeki Matsumura

e-mail: smatsumu@pi.titech.ac.jp
Precision & Intelligence Laboratory,
Tokyo Institute of Technology,
14-4 Nagatsuta 4259, Midori-ku,
Yokohama 226-8503, Japan

Contributed by Power Transmission and Gearing Committee of ASME for publication in the Journal of Mechanical Design. Manuscript received June 11, 2012; final manuscript received October 28, 2012; published online January 29, 2013. Assoc. Editor: Qi Fan.

J. Mech. Des 135(3), 034504 (Jan 29, 2013) (8 pages) Paper No: MD-12-1303; doi: 10.1115/1.4023324 History: Received June 11, 2012; Revised October 28, 2012

Straight bevel gears are widely used in the plant of large-sized power generation when the gears have large size. The purpose of this study is to manufacture the large-sized straight bevel gears with equi-depth teeth on a multitasking machine. The manufacturing method has the advantages of arbitrary modification of the tooth surface and machining of the part without the tooth surface. For this study, first, the mathematical model of straight bevel gears by complementary crown gears considering manufacture on multitasking machine is proposed, and the tooth contact pattern and transmission errors of these straight bevel gears with modified tooth surfaces are analyzed in order to clarify the meshing and contact of these gears. Next, the numerical coordinates on the tooth surfaces of the bevel gears are calculated and the tooth profiles are modeled using a 3D-Computer-Aided Design (CAD) system. Five-axis control machines were utilized. The gear-work was machined by a swarf cutting using a coated carbide end mill. After rough cutting, the gear-work was heat-treated, and it was finished based on a Computer-Aided Manufacturing (CAM) process through the calculated numerical coordinates. The pinion was also machined similarly. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. As a result, the obtained tooth flank form errors were small. In addition, the tooth contact pattern of the manufactured large-sized straight bevel gears was compared with those of tooth contact analysis. The data showed good agreement.

Copyright © 2013 by ASME
Topics: Machinery , Gears , Cutting
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References

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Figures

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Fig. 1

Pitch cones of straight bevel gears

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Fig. 2

Tooth surface of complementary crown gear

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Fig. 3

Relationship between complementary crown gear and work-peices

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Fig. 4

Meshing of pinion and gear

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Fig. 5

Results of tooth contact analysis in the case of Δc = 0.05 mm and Δs = 0.03 mm

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Fig. 6

Results of tooth contact analysis in the case of Δc = 0.02 mm and Δs = 0.03 mm

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Fig. 7

Results of tooth contact analysis in the case of Δc = 0.05 mm and Δs = 0.01 mm

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Fig. 8

Tooth profile of gear modeled using 3D-CAD system

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Fig. 9

Tooth profile of pinion modeled using 3D-CAD system

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Fig. 10

Gear-work on multitasking machine

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Fig. 11

Swarf cutting of gear

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Fig. 12

Pinion-work on multi-tasking machine

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Fig. 13

Measured result of gear (μm)

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Fig. 14

Measured result of pinion (μm)

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Fig. 15

Tooth contact pattern of straight bevel gears

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