A Study of select the apropos processing mechanical method by the presume of transformation of teeth s surface degree
ABSTRACT This study has been tried to select the apropos processing method by the presume of transformation of teeth s surface degree and form because of the cutting method of teeth during the gear finishing processing. Because of these transformation,mechanical noise and vibration occurred and it made a factor to reduce the good mechanism. Especially,if it does not concern the finishing processing after the teeth s rough cutting,it was difficult to get the precision goods because of the transformation of teeth s side degree and form. Therefore,we have studied to get the high precise teeth surface through various method. For the material of the gear cutting test,sm45c was been used for the concerning of cutting feature and heating feature to improve the confidence on the test. For the cutting tool,the Hob made by Koepfer in Germany was used for the rough cutting and finishing cutting, for it is difficult to produce in Korean. For the Gear teeth s finishing method, skiving,shaving and grinding have been used. Also, cutting tools made in Germany have been used. After each finishing processing, the data of teeth s form after the cutting teeth have been made by the gear tester made in Japan. It has been found that the transformation of teeth through the processing rough cutting, heating,finishing cutting and these transformation obstructed the apropos mechanism. And, during the measuring, the importance factor of the differences by the various processing instruments was indicated,so, it is very important to set the instruments precisely at the starting time of processing.
The result of the above conditions have been carefully considered,it was possible to get the high precise gear.because of the available of the presume,selecting, it brought the economic. As the result,according to the finishing processing,the differences of JIS O-4 grade have been shown, because of it, the importance of finishing processing was been indicated. The test result showed that the teeth s form could be stable safe according to the first of all the shaving, the next skiving, and Grinding.
List of Figures Fig.2-1 Involute formation during hobbing through enveloping cuts-------------3 Fig.2-2 (a)accomplishment hob picture-----------------------------------------------4 Fig.2-2 (b)measuring instrument-------------------------------------------------------4 Fig.2-3 (a)hob tooth profile-------------------------------------------------------------5 Fig.2-3 (b)gear tooth profile------------------------------------------------------------5 Fig.3-1 drawing of machining----------------------------------------------------------7 Fig.3-2 CNC hobbing m/c--------------------------------------------------------------8 Fig.3-3 scene of teeth s cutting---------------------------------------------------------9 Fig.3-4 gear tooth profile & lead(rough machining)--------------------------------11 Fig.3-5 gear tooth profile & lead(heat treatment)-----------------------------------13 Fig.3-6 gear tooth profile & lead(finishing of skiving)-----------------------------15 Fig.3-7 drawing of machining---------------------------------------------------------17 Fig.3-8 CNC hobbing m/c--------------------------------------------------------------18 Fig.3-9 scene of teeth s cutting--------------------------------------------------------19 Fig.3-10 scene of shaving cutting-----------------------------------------------------20 Fig.3-11 gear tooth profile & lead(rough machining)------------------------------22 Fig.3-12 gear tooth profile & lead(finishing of shaving)---------------------------24 Fig.3-13 gear tooth profile & lead(heat treatment)----------------------------------26 Fig.3-14 drawing of machining--------------------------------------------------------28 Fig.3-15 grinding m/c-------------------------------------------------------------------29 Fig.3-16 scene of teeth s grinding-----------------------------------------------------30 Fig.3-17 gear tooth profile & lead(rough machining)------------------------------32 Fig.3-18 gear tooth profile & lead(heat treatment)---------------------------------34 Fig.3-19 gear tooth profile & lead(finishing of grinding)--------------------------36 Fig.4-1 schematic diagram of measurement profile--------------------------------38 Fig.4-2 schematic diagram of measurement lead-----------------------------------39 Fig.4-3 measuring of tooth profile----------------------------------------------------40 Fig.4-4 measuring of tooth lead-------------------------------------------------------40 Fig.4-5 explanation graph of profile--------------------------------------------------41 Fig.4-6 explanation graph of lead-----------------------------------------------------41 Fig.4-7 CNC gear tester----------------------------------------------------------------42 Fig.4-8 scene of gear measuring-------------------------------------------------------42
List of Figures Fig.4-9 comparative of result to skiving method(profile)-----------------------43 Fig.4-10 comparative of result to shaving method (profile)--------------------44 Fig.4-11 comparative of result to grinding method (profile)-------------------45 Fig.4-12 comparative of result to skiving method(lead)------------------------46 Fig.4-13 comparative of result to shaving method lead)------------------------47 Fig.4-14 comparative of result to grinding method (lead)----------------------48 Fig.4-15 comparative of result to finishing(profile)-----------------------------49 Fig.4-16 comparative of result to finishing(lead)--------------------------------49 Fig.5-1 influence of hob preponderance-------------------------------------------51 Fig.5-2 influence of hob shaft torsion----------------------------------------------52 Fig.5-3 influence of hob shaft torsion----------------------------------------------53 Fig.5-4 influence of used RH/LH hob----------------------------------------------54 Fig.5-5 influence of hob processing------------------------------------------------55 Fig.5-6 influence of hob arbor diameter-------------------------------------------56
List of Tables Table.2-1 selection of hob data----------------------------------------------------------5 Table.2-2 grinding stock------------------------------------------------------------------6 Table.2-3 shaving stock-------------------------------------------------------------------6 Table.3-1 machining data-----------------------------------------------------------------7 Table.3-2 specification of CNC hobbing m/c------------------------------------------8 Table.3-3 condition of machining-------------------------------------------------------9 Table.3-4 machining data----------------------------------------------------------------17 Table.3-5 specification of CNC hobbing m/c-----------------------------------------18 Table.3-6 condition of machining------------------------------------------------------19 Table.3-7 condition of shaving---------------------------------------------------------20 Table.3-8 machining data---------------------------------------------------------------28 Table.3-9 specification of grinding m/c-----------------------------------------------29 Table.3-10 condition of machining----------------------------------------------------30 Table.4-1 specification of CNC gear tester-------------------------------------------42 Table.4-2 measured data of skiving(profile)------------------------------------------43 Table.4-3 measured data of shaving(profile)-----------------------------------------44 Table.4-4 measured data of grinding(profile)----------------------------------------45 Table.4-5 measured data of skiving(lead)--------------------------------------------46 Table.4-6 measured data of shaving(lead)--------------------------------------------47 Table.4-7 measured data of grinding(lead)-------------------------------------------48 Table.4-8 measured data of finishing(profile)----------------------------------------49 Table.4-9 measured data of finishing(lead)-------------------------------------------49 Table.4-10 standard grade of KS,JIS,DIN--------------------------------------------50
Fig.2-1 Involute Formation During Hobbing Through Enveloping Cuts
Fig.2-2 (a)accomplishment hob picture Fig.2-2 (b)measuring instrument
0 PRO Fig.2-3 (a) hob tooth profile Fig.2-3 (b) gear tooth profile
1 H7 6 +0.018 0 51.33 0-0 5 0. 49.33 10 0-0.1 C0.5
MAKER CONTROLLER
2 H7 2 +0.021 0 75.20 0. -0. 1 72 792. 12 0-0.1 C0.5 HELICAL GEAR
1 H7 8 +0.01 0 6 4 1. 0-0 7 0. 6 1 6. 12 0-0.1 C0.5 HELICAL GEAR
GRINDING REISHAUER REISHAUER REISHAUER
INTERFACE COUNTER A.D CONNECTOR CONTROLLER COUNTER CPU DATA BELLOWS MOTOR LINER ENCODER ROTARY ENCODER x
INTERFACE COUNTER A.D CONNECTOR CONTROLLER COUNTER CPU ROTARY ENCODER BELLOWS MOTOR BELLOWS MOTOR LINER ENCODER BASIC TABLE DATA
4 divide stylus 4 divide stylus
FF Faj FEj FQ FHj FEj
TTI TOKYO TECH 0.1
3 2 1 3 0 10m
0 50mm 40m 8m 20m 50m top bottom
0 50mm 40m 4m 15m 45m top bottom f=4.5mm/rev f=1.0mm/rev f=0.75mm/rev
LH RH 50mm f=0.25mm/rev top f=0.4mm/rev 0 bottom 12m 15m 40m 8HOB
LH RH HOB
0 50mm 50m 84m top bottom 22mm HOB 31.75