Académique Documents
Professionnel Documents
Culture Documents
June , 2007
by Sven Hoose
Contents
Introduction
Part 1 Gear Metrology
Basics of Gear Metrology Deviations Strategies for efficient inspection
Contents
Introduction
Part 1 Gear Metrology
Basics of Gear Metrology Deviations Strategies for efficient inspection
Profile Inspection
The characteristics of Lead Deviations are being measured and evaluated at the middle of the Tooth Height. The Lead Inspection defines the Form and location of the tooth flank without influence of other parameters.
The characteristics of Profile Deviations are being measured and evaluated perpendicular to the involute form. The Profile Inspection defines the Form and location of the involute form without influence of other parameters.
The characteristics of Pitch Deviations are being measured and evaluated at the middle of the tooth height and describing the middle location of all right and left flanks to each other.
The characteristics of Runout devaitions measured and evaluated at the middle of the tooth height and describing the radial location of all teeth related to the pitch circle..
The characteristics of Tooth Thickness is defined as the length of a circular arc at the pitch circle between both flanks of each tooth.
Contents
Introduction
Part 1 Gear Metrology
Basics of Gear Metrology Deviations Strategies for efficient inspection
ffb Lead form Form Variation Is defined as the difference between the Nominal Lead Form line to the actual form line.
Fhb Lead Angle Variation Is defined as the difference between the Nominal Helix Angle to the actual Helix angle.
Fb Total Lead Variation Is defined as the sum of the both, the Lead Form and Lead Angle deviation.
ffa Profile Form Variation Is defined as the difference between the Nominal Involute Form to the actual Involute form .
fha Profile Angle Variation Is defined as the difference between the Nominal Involute Angle to the actual Involute angle.
Fa Total Profile Variation Is defined as the sum of the both, the Profile Form and Angle deviation.
fp Single Pitch variation Is defined as the difference between the Nominal angular position of each flank to the previous flank at the same side
Fp Total pitch variation Is defined as the the maximum difference between the Nominal angular position of each right and left flanks to the actual measured position.
Fr Run out Variation Is defined as the maximum difference of the Nominal radial position of all teeth to the actual measured position.
Contents
Introduction
Part 1 Gear Metrology
Basics of Gear Metrology Deviations Strategies for efficient inspection
Contents
Introduction
Part 1 Gear Metrology
Basics of Gear Metrology Deviations Strategies for efficient inspection
1) Incorrect hob sharpening. The hob has been sharpened with positive rake error making the hob tooth larger toward the outside diameter and the gear tooth smaller. 2) Incorrect swivel angle setting on the hobbing machine. 3) Bad hob.
Summary
The examples shown in this presentation are isolated to a particular error. In actual troubleshooting multiple problems will occur and compound the complexity of the resulting inspection charts. These examples should be used as a guide in the solution your problem, with the goal of Probable cause / to check step-by-step correction
1) The work piece blank has radial runout or the blank has face wobble, resulting in excessive axial runout. 2) The work piece mounting fixture has radial or axial runout. 3) The gear teeth have excessive lead variation. 4) The hobbing machine work spindle or index drive system is worn or has runout.
Contents
Introduction
Part 1 Gear Metrology
Basics of Gear Metrology Deviations Strategies for efficient inspection
REM picture of fine pitting Counteractive measures: a) Higher purity grade of the material b) Ground Tooth flanks c) Detailed monitoring of heat treatment operations d) comprehensive inspection of - Surface Hardness - Hardness profile - Microstructure
Fatigue Crack at Gear Tooth Root Fillet Counteractive measures: a) Check Root tooth pressure strength b) Check undercut options c) Groove free Root fillet area
Target : The study shows that the micro pitting area is radically larger when the gear surface roughness is close to the upper limit of the range studied. Plasticity index, which approaches a value of around 3.7 for the rougher gear surface, appears to be responsible for the formation of such a large micro pitting area. At the same time, the formation of a pit is also greatly delayed. Not only is the pitting life significantly longer, but the initiation of pits can occur near the pitch line.
SEM pictures of different Surface structures Result: The study here confirms that within the family of pitting gears, which have a surface roughness value around 0.3m, the rougher surface will decrease the pitting life
Basic Tests
Surface hardness and roughness. Magnetic particle inspection. Gear tooth accuracy inspection.
Advanced Tests
Micro hardness survey. Micro structural determination using various acid etches. Determination of grain size. Determination of nonmetallic inclusions.