Advanced Gear Manufacturing and Finishing : Classical and Modern Processes

Advanced Gear Manufacturing and Finishing offers detailed coverage of advanced manufacturing technologies used in the production of gears, including new methods such as spark erosion machining, abrasive water jet machining, additive layer manufacturing, laser shaping, and sustainable manufacturing of gears. The industry in this area is constantly producing new settings where gears must endure ever increasing stresses, strains, and temperatures. Advanced methods in manufacturing, finishing, and surface property enhancement have emerged in recent years to meet these challenges. This unique book takes a critical look at the state-of-the-art research into these new methods, and the latest improvements to classic technologies in both gear manufacturing and finishing. This book is essential reading for researchers and engineers working in the fields of powertrain manufacturing, gear technology, and advanced manufacturing technologies. Describes the machining systems, main components, and working procedures with the help of diagrams and photos. Demonstrates the mechanisms and capabilities of new methods. Shows improvements to a range of gear manufacturing and finishing technologies. Provides a critical review of recent research in a range of fields relevant to gear manufacturing technologies. Advanced Gear Manufacturing and Finishing: Classical and Modern Processes, (2017) 242pp. 978-0-12-804460-5 Front Cover 1 Advanced Gear Manufacturing and Finishing 4 Copyright Page 5 Contents 6 Preface 10 1 Introduction to Gear Engineering 12 1.1 Introduction and History of Gears 12 1.1.1 Introduction 12 1.1.2 History 12 1.2 Classification and Gear Types 14 1.2.1 Parallel-Shaft Gears 14 1.2.2 Intersecting-Shaft Gears 20 1.2.3 Nonparallel Nonintersecting-Shaft Gears 23 1.2.4 Some Special Gear Types 25 1.3 Gear Terminology 28 1.3.1 Standard Gear Tooth Proportions 32 1.4 Gear Materials 32 1.4.1 Ferrous Metals and Alloys 33 1.4.1.1 Cast Iron 33 1.4.1.2 Steel 33 1.4.2 Nonferrous Metals and Alloys 38 1.4.2.1 Copper Alloys 38 1.4.2.2 Aluminum Alloy 39 1.4.3 Nonmetals 39 1.5 Gear Manufacture 40 1.5.1 Conventional Gear Manufacturing 41 1.5.2 Conventional Gear Finishing 42 1.5.3 Advances in Gear Manufacturing and Finishing 43 References 44 2 Conventional Manufacturing of Cylindrical Gears 46 2.1 Subtractive or Material Removal Processes 46 2.1.1 Form Cutting 46 2.1.1.1 Gear Milling 46 2.1.1.2 Gear Broaching 47 2.1.1.3 Gear Cutting on a Shaper 48 2.1.1.4 Shear Cutting 49 2.1.2 Generative Processes 49 2.1.2.1 Gear Hobbing 50 2.1.2.1.1 Axial Hobbing 50 2.1.2.1.2 Radial Hobbing 50 2.1.2.1.3 Tangential Hobbing 50 2.1.2.2 Gear Shaping 50 2.1.2.3 Gear Planing 51 2.2 Forming Processes 53 2.2.1 Stamping and Fine Blanking 54 2.2.2 Extrusion and Cold Drawing 55 2.2.3 Gear Rolling 55 2.2.4 Gear Forging 58 2.3 Additive Processes 58 2.3.1 Gear Casting 58 2.3.2 Powder Metallurgy 60 2.3.3 Injection Molding of Plastic Gears 61 References 62 3 Manufacturing of Conical and Noncircular Gears 64 3.1 Manufacturing of Conical Gears by Machining 64 3.1.1 Generative Machining Processes for Conical Gears 66 3.1.1.1 Face Milling 66 3.1.1.2 Face Hobbing 68 3.1.1.3 Generation by Interlocking Cutters 68 3.1.1.4 Generation by Revacycle Cutters 69 3.1.1.5 Shaping by Two-Tool Generators 70 3.1.1.6 Planning Generators 72 3.1.2 Nongenerative Machining Processes for Conical Gears 73 3.1.2.1 Formate Machining 73 3.1.2.2 Helixform Machining 73 3.1.2.3 Template Machining and Cyclex Machining 73 3.2 Manufacturing of Noncircular Gears 74 References 76 4 Advances in Gear Manufacturing 78 4.1 Subtractive or Material Removal Processes 79 4.1.1 Laser Machining 79 4.1.1.1 Introduction 79 4.1.1.2 Working Principle, Process Mechanism, and Significant Process Parameters 79 4.1.1.3 Laser Systems for Gear Manufacturing 81 4.1.2 Abrasive Water Jet Machining 82 4.1.2.1 History and Developments 82 4.1.2.2 Working Principle, Process Mechanism, and Significant Process Parameters 82 4.1.2.3 Machining of Gears by Abrasive Water Jet Machining 85 4.1.2.4 Advantages of Abrasive Water Jet Machining for Gear Manufacturing 86 4.1.3 Spark Erosion Machining 87 4.1.3.1 Introduction and History 88 4.1.3.2 Manufacturing of Gears by Wire Spark Erosion Machining Processes 89 4.1.3.2.1 Working Principle and Significant Process Parameters 89 4.1.3.2.2 Mechanism of Material Removal 91 4.1.3.3 Recent Investigations 93 4.1.3.4 Advantages, Capabilities, and Limitations 95 4.2 Additive or Accretion Processes 97 4.2.1 Metal Injection Molding 97 4.2.1.1 Working Principle 97 4.2.1.2 Capabilities, Advantages, Limitations, and Applications 99 4.2.2 Injection Compression Molding 100 4.2.2.1 Working Principle 100 4.2.2.2 Capabilities, Advantages, Limitations, and Applications 101 4.2.3 Micropowder Injection Molding 101 4.2.3.1 Working Principle 102 4.2.3.2 Capabilities, Advantages, Limitations, and Applications 103 4.2.4 Additive Layer Manufacturing Processes 104 4.2.4.1 Introduction, History, and Development 104 4.2.4.2 Additive Layer Manufacturing Processes Steps for Gear Manufacture 105 4.2.4.3 Stereolithography 106 4.2.4.4 Selective Laser Sintering 109 4.2.4.5 3D-Printing 110 4.2.4.6 Fused Deposition Modeling 112 4.2.4.7 Advantages of Additive Layer Manufacturing for Gear Manufacturing 113 4.2.4.8 Factors Influencing Part Accuracy of Additive Layer Manufacturing 114 4.3 Deforming Processes 115 4.3.1 Hot Embossing 115 4.3.1.1 Working Principle 115 4.3.1.2 Capabilities, Advantages, Limitations, and Applications 116 4.3.2 Fine Blanking 117 4.4 Hybrid Processes 118 4.4.1 Lithographie, Galvanoformung and Abformung 118 4.4.1.1 Working Principle 118 4.4.1.2 Capabilities, Advantages, Limitations, and Applications 120 4.5 Sustainable Manufacturing of Gears 120 4.5.1 Challenges and Opportunities 121 4.5.2 Environment-Friendly Lubricants and Lubrication Techniques 123 4.5.2.1 Dry-Hobbing 123 4.5.2.1.1 Overview 123 4.5.2.1.2 Requirements for Effective Dry-Hobbing 124 4.5.2.1.3 Benefits 125 4.5.2.2 Minimum Quantity Lubrication Assisted Machining of Gears 126 4.5.2.2.1 Overview 126 4.5.2.2.2 Working Principle and Mechanism 126 4.5.3 Recent Investigations 129 References 131 5 Conventional and Advanced Finishing of Gears 138 5.1 Conventional Finishing Processes for Gears 139 5.1.1 Gear Shaving 143 5.1.2 Gear Grinding 146 5.1.3 Gear Honing 149 5.1.4 Gear Lapping 151 5.1.5 Gear Burnishing 153 5.1.6 Gear Skiving 153 5.2 Advanced Finishing Processes for Gears 155 5.2.1 Gear Finishing by Electrochemical Honing 155 5.2.1.1 ECH of Cylindrical Gears 159 5.2.1.2 ECH of Conical Gears 160 5.2.2 Gear Finishing by Electrochemical Grinding 162 5.2.3 Gear Finishing by Abrasive Flow Finishing (AFF) 162 5.2.4 Other Advanced Finishing Processes for Gears 165 5.2.4.1 Water-Jet Deburring 165 5.2.4.2 Electrolytic Deburring 168 5.2.4.3 Deburring by Thermal Energy Method 169 5.2.4.4 Brush Deburring 170 5.2.4.5 Chemically Accelerated Vibratory Surface Finishing 172 5.2.4.6 Black Oxide Finishing 173 References 175 6 Surface Property Enhancement of Gears 178 6.1 The Need for Surface Modification of Gears 178 6.2 Gear Surface Modification Techniques 179 6.2.1 Case Hardening of Gear-Teeth Surfaces 180 6.2.2 Coating the Gear-Teeth Surfaces 180 6.2.3 Mechanical Hardening of Gear-Teeth Surfaces 180 6.3 Gear Coatings 181 6.3.1 Introduction and Coating Types 181 6.3.2 Types of Coatings for Gears 181 6.3.3 Coating Methods 182 6.3.3.1 Vapor Deposition or Thin-Film Coating Methods 183 6.3.3.1.1 Sputtering Physical Vapor Deposition 184 6.3.3.1.2 Plasma-Enhanced Chemical Vapor Deposition 186 6.3.4 Testing and Inspection of Gear Coatings 187 6.3.4.1 Scuffing Test 189 6.3.4.2 Pitting Test 189 6.3.5 Past Work on Improving Tribological Characteristics of Gears Using Various Coating Types 191 6.4 Surface Hardening of Gears 193 6.4.1 Mechanical Hardening 193 6.4.1.1 Shot Peening 193 6.4.1.2 Ultrasonic Shot Peening 195 6.4.1.3 Laser Peening 197 6.4.1.4 Cavitation Water Jet Shotless Peening 198 6.4.2 Case-Hardening 200 6.4.2.1 Plasma Nitriding 201 6.4.2.2 Induction and Flame Hardening 202 6.4.2.2.1 Induction Hardening 202 6.4.2.2.2 Flame Hardening 204 References 205 7 Measurement of Gear Accuracy 208 7.1 Gear Accuracy 208 7.1.1 Macrogeometry Parameters 209 7.1.2 Microgeometry Parameters 210 7.1.2.1 Profile and Profile Errors 210 7.1.2.2 Lead and Lead Errors 213 7.1.2.3 Pitch Error and Runout 214 7.2 Gear Tolerances and Standards 215 7.3 Measurement of Gear Accuracy 216 7.3.1 Analytical Gear Inspection 216 7.3.1.1 Macrogeometry Measurement 217 7.3.1.2 Microgeometry Measurement 218 7.3.1.2.1 Profile and Lead Measurement 219 7.3.1.2.2 Pitch and Runout Measurement 222 7.3.2 Functional Gear Inspection 223 7.3.2.1 Double-Flank Inspection 224 7.3.2.2 Single-Flank Inspection 226 References 228 Index 230 Back Cover 242 "Advanced Gear Manufacturing and Finishing offers detailed coverage of advanced manufacturing technologies used in the production of gears, including new methods such as spark erosion machining, abrasive water jet machining, additive layer manufacturing, laser shaping, and sustainable manufacturing of gears."--Page 4 of cover