Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
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Tractor front shaft
① Axle Housing ② Connect Case ③ Connect Arm④ Gear Case⑤ Gear Housing⑥ Drive Differential Comp⑦ 1st Bevel Gear ⑧ Final Bevel Gear⑨ Final Pinion Gear ⑩ Wheel Shaft
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Bevel Gear Process
Forging Turning BroachingStraight Bevel Carburizing
Pinion Gear
Forging Turning BroachingStraight Bevel GrindingCarburizing
Bevel Gear
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Bevel Cutting
FACE MILLINGHARDAC cutter
http://www.youtube.com/watch?v=8pXtSWIJ7Ac Bevel Cutting (40s)http://www.youtube.com/watch?v=fOLaJMh6DXQ 3-axis Machining (12s)
NC machiningLow productivity
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Gear Lapping
• Liquid abrasive compound is feed into the rotating gear pairs to smooth teeth surfaces.
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Broach
The broach is run linearly against a surface of the workpiece to effect the cut.
BROACH CUTTER
http://www.youtube.com/watch?v=2K45B6tDqsg Gear Broach
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Inspection
ITEMS
SPEC.
(JIS 4)
DATA (LH/RH) RESULT
Pitch Variation 56 46/42 O.K
Pitch Error 73 68/61 O.K
Accumulative Pitch Error 230 101/106 O.K
Run-out 100 77 O.K
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
InspectionITEMS
SPEC. (JIS 4)
DATA(LH/RH) RESULT
Pitch Variation 62 23/27 O.K
Pitch Error 81 39/45 O.K
Accumulative Pitch Error 250 157/194 O.K
Run-out 200 165 O.K
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Inspection
Standard Contact Area Contact Area Inspection
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Bebel Gear Forging
Gear designGear design
Forging simulationForging simulation
Die MachiningDie Machining
ForgingForging
InspectionInspection
http://www.afdex.com
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Forging simulation
<12T Bevel gear>
<20T Bevel gear>
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Die machining
<12T Bevel gear> <20T Bevel gear>
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Forging
Closed forging die
Press machine
Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes
© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU
Forged bevel gear
<12T Bevel gear> <20T Bevel gear>