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Advanced Gear Manufacturing and Finishing

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Contents

Preface

1 Introduction to Gear Engineering

1.1 Introduction and History of Gears

1.1.1 Introduction

1.1.2 History

1.2 Classification and Gear Types

1.2.1 Parallel-Shaft Gears

1.2.2 Intersecting-Shaft Gears

1.2.3 Nonparallel Nonintersecting-Shaft Gears

1.2.4 Some Special Gear Types

1.3 Gear Terminology

1.3.1 Standard Gear Tooth Proportions

1.4 Gear Materials

1.4.1 Ferrous Metals and Alloys

1.4.1.1 Cast Iron

1.4.1.2 Steel

1.4.2 Nonferrous Metals and Alloys

1.4.2.1 Copper Alloys

1.4.2.2 Aluminum Alloy

1.4.3 Nonmetals

1.5 Gear Manufacture

1.5.1 Conventional Gear Manufacturing

1.5.2 Conventional Gear Finishing

1.5.3 Advances in Gear Manufacturing and Finishing

References

2 Conventional Manufacturing of Cylindrical Gears

2.1 Subtractive or Material Removal Processes

2.1.1 Form Cutting

2.1.1.1 Gear Milling

2.1.1.2 Gear Broaching

2.1.1.3 Gear Cutting on a Shaper

2.1.1.4 Shear Cutting

2.1.2 Generative Processes

2.1.2.1 Gear Hobbing

2.1.2.1.1 Axial Hobbing

2.1.2.1.2 Radial Hobbing

2.1.2.1.3 Tangential Hobbing

2.1.2.2 Gear Shaping

2.1.2.3 Gear Planing

2.2 Forming Processes

2.2.1 Stamping and Fine Blanking

2.2.2 Extrusion and Cold Drawing

2.2.3 Gear Rolling

2.2.4 Gear Forging

2.3 Additive Processes

2.3.1 Gear Casting

2.3.2 Powder Metallurgy

2.3.3 Injection Molding of Plastic Gears

References

3 Manufacturing of Conical and Noncircular Gears

3.1 Manufacturing of Conical Gears by Machining

3.1.1 Generative Machining Processes for Conical Gears

3.1.1.1 Face Milling

3.1.1.2 Face Hobbing

3.1.1.3 Generation by Interlocking Cutters

3.1.1.4 Generation by Revacycle Cutters

3.1.1.5 Shaping by Two-Tool Generators

3.1.1.6 Planning Generators

3.1.2 Nongenerative Machining Processes for Conical Gears

3.1.2.1 Formate Machining

3.1.2.2 Helixform Machining

3.1.2.3 Template Machining and Cyclex Machining

3.2 Manufacturing of Noncircular Gears

References

4 Advances in Gear Manufacturing

4.1 Subtractive or Material Removal Processes

4.1.1 Laser Machining

4.1.1.1 Introduction

4.1.1.2 Working Principle, Process Mechanism, and Significant Process Parameters

4.1.1.3 Laser Systems for Gear Manufacturing

4.1.2 Abrasive Water Jet Machining

4.1.2.1 History and Developments

4.1.2.2 Working Principle, Process Mechanism, and Significant Process Parameters

4.1.2.3 Machining of Gears by Abrasive Water Jet Machining

4.1.2.4 Advantages of Abrasive Water Jet Machining for Gear Manufacturing

4.1.3 Spark Erosion Machining

4.1.3.1 Introduction and History

4.1.3.2 Manufacturing of Gears by Wire Spark Erosion Machining Processes

4.1.3.2.1 Working Principle and Significant Process Parameters

4.1.3.2.2 Mechanism of Material Removal

4.1.3.3 Recent Investigations

4.1.3.4 Advantages, Capabilities, and Limitations

4.2 Additive or Accretion Processes

4.2.1 Metal Injection Molding

4.2.1.1 Working Principle

4.2.1.2 Capabilities, Advantages, Limitations, and Applications

4.2.2 Injection Compression Molding

4.2.2.1 Working Principle

4.2.2.2 Capabilities, Advantages, Limitations, and Applications

4.2.3 Micropowder Injection Molding

4.2.3.1 Working Principle

4.2.3.2 Capabilities, Advantages, Limitations, and Applications

4.2.4 Additive Layer Manufacturing Processes

4.2.4.1 Introduction, History, and Development

4.2.4.2 Additive Layer Manufacturing Processes Steps for Gear Manufacture

4.2.4.3 Stereolithography

4.2.4.4 Selective Laser Sintering

4.2.4.5 3D-Printing

4.2.4.6 Fused Deposition Modeling

4.2.4.7 Advantages of Additive Layer Manufacturing for Gear Manufacturing

4.2.4.8 Factors Influencing Part Accuracy of Additive Layer Manufacturing

4.3 Deforming Processes

4.3.1 Hot Embossing

4.3.1.1 Working Principle

4.3.1.2 Capabilities, Advantages, Limitations, and Applications

4.3.2 Fine Blanking

4.4 Hybrid Processes

4.4.1 Lithographie, Galvanoformung and Abformung

4.4.1.1 Working Principle

4.4.1.2 Capabilities, Advantages, Limitations, and Applications

4.5 Sustainable Manufacturing of Gears

4.5.1 Challenges and Opportunities

4.5.2 Environment-Friendly Lubricants and Lubrication Techniques

4.5.2.1 Dry-Hobbing

4.5.2.1.1 Overview

4.5.2.1.2 Requirements for Effective Dry-Hobbing

4.5.2.1.3 Benefits

4.5.2.2 Minimum Quantity Lubrication Assisted Machining of Gears

4.5.2.2.1 Overview

4.5.2.2.2 Working Principle and Mechanism

4.5.3 Recent Investigations

References

5 Conventional and Advanced Finishing of Gears

5.1 Conventional Finishing Processes for Gears

5.1.1 Gear Shaving

5.1.2 Gear Grinding

5.1.3 Gear Honing

5.1.4 Gear Lapping

5.1.5 Gear Burnishing

5.1.6 Gear Skiving

5.2 Advanced Finishing Processes for Gears

5.2.1 Gear Finishing by Electrochemical Honing

5.2.1.1 ECH of Cylindrical Gears

5.2.1.2 ECH of Conical Gears

5.2.2 Gear Finishing by Electrochemical Grinding

5.2.3 Gear Finishing by Abrasive Flow Finishing (AFF)

5.2.4 Other Advanced Finishing Processes for Gears

5.2.4.1 Water-Jet Deburring

5.2.4.2 Electrolytic Deburring

5.2.4.3 Deburring by Thermal Energy Method

5.2.4.4 Brush Deburring

5.2.4.5 Chemically Accelerated Vibratory Surface Finishing

5.2.4.6 Black Oxide Finishing

References

6 Surface Property Enhancement of Gears

6.1 The Need for Surface Modification of Gears

6.2 Gear Surface Modification Techniques

6.2.1 Case Hardening of Gear-Teeth Surfaces

6.2.2 Coating the Gear-Teeth Surfaces

6.2.3 Mechanical Hardening of Gear-Teeth Surfaces

6.3 Gear Coatings

6.3.1 Introduction and Coating Types

6.3.2 Types of Coatings for Gears

6.3.3 Coating Methods

6.3.3.1 Vapor Deposition or Thin-Film Coating Methods

6.3.3.1.1 Sputtering Physical Vapor Deposition

6.3.3.1.2 Plasma-Enhanced Chemical Vapor Deposition

6.3.4 Testing and Inspection of Gear Coatings

6.3.4.1 Scuffing Test

6.3.4.2 Pitting Test

6.3.5 Past Work on Improving Tribological Characteristics of Gears Using Various Coating Types

6.4 Surface Hardening of Gears

6.4.1 Mechanical Hardening

6.4.1.1 Shot Peening

6.4.1.2 Ultrasonic Shot Peening

6.4.1.3 Laser Peening

6.4.1.4 Cavitation Water Jet Shotless Peening

6.4.2 Case-Hardening

6.4.2.1 Plasma Nitriding

6.4.2.2 Induction and Flame Hardening

6.4.2.2.1 Induction Hardening

6.4.2.2.2 Flame Hardening

References

7 Measurement of Gear Accuracy

7.1 Gear Accuracy

7.1.1 Macrogeometry Parameters

7.1.2 Microgeometry Parameters

7.1.2.1 Profile and Profile Errors

7.1.2.2 Lead and Lead Errors

7.1.2.3 Pitch Error and Runout

7.2 Gear Tolerances and Standards

7.3 Measurement of Gear Accuracy

7.3.1 Analytical Gear Inspection

7.3.1.1 Macrogeometry Measurement

7.3.1.2 Microgeometry Measurement

7.3.1.2.1 Profile and Lead Measurement

7.3.1.2.2 Pitch and Runout Measurement

7.3.2 Functional Gear Inspection

7.3.2.1 Double-Flank Inspection

7.3.2.2 Single-Flank Inspection

References

Index

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