Gear Shaft.ppt [호환 모드] - Manufacturing Laboratoryma.gnu.ac.kr/course/mp/15_Gear.pdf · ·...

Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU

Manufacturing Process

Gear & Shaft Manufacturing

Associate Professor Su-Jin Kim

School of Mechanical EngineeringGyeongsang National University


[모듈 공급업체]현대모비스한라공조

Powertrain Module

[생산업체]현대위아S&T중공업

에스엘경창산업

Transmission

[생산업체]현대모비스모토닉, 지코

화신, S&T대우한국프랜지SJM, 현대EP

Engine

Powertrain Module of Automobile


Index

1. Introduction of Gear2. Gear Machining3. Shaft & Gear Forming4. Bevel Cutting5. Bevel Forging


Gear

• Super, Helical• Bevel(Straight, Spiral, Hypoid)• Worm• Shaft & Spline


Gear Hob

• Pitch• Gear Hob

© 2011 정영석, 세일공업

http://ma.gnu.kr/vod/Machining/Gear_Hob_Sim.avi Gear Hob Sim (20s)http://www.youtube.com/watch?v=aCRt6yVhXf0 Bevel Gear Sim (3min)


Hobbing

• A hob (cutter) is rotated one revolution to transfer each tooth profile onto a rotating gear blank.

• Used very often for medium to high sizes of production runs.

http://www.youtube.com/watch?v=TDzhSaSZrSg Gleason P90 Gear Hobber, 3 min


Gear Shaper

Interferencehttp://www.youtube.com/watch?v=Dd9Ekl9DPZg (60s)http://www.youtube.com/watch?v=CHQ1ZABx68o (140s)

• The cutter engages the part on the forward stroke and pulls away from the part on the return stroke.


Gear heat treatment

http://www.youtube.com/watch?v=iI7QEI2g0lk (90s)

• Carburzing of Gears• Induction Hardening of Gears• Ferritic Nitrocarburizing of Gears


Gear Grinding

• Gear is grinded after heat treat to give fine finish and high accuracy.

http://www.youtube.com/watch?v=w9x7BjDhxSs Gleason 1500G Titan 10min

CNC gear grinderRough grinding Finish grinding


Gear Machining Process of TICRing Gear공정 Flow

선삭 수입검사 치절(황삭/정삭) 열처리 내경정삭

Pinion Gear공정 Flow

선삭 수입검사 치절(황삭/정삭/정삭) 열처리 외경 완성 연마

래핑/Test공정 Flow(Set화)

래핑 디버링 / 세척 TEST


Shaft & Gear forming of KMC

© 2011 김홍철 KMC


Shaft & Gear forming ProcessFORMER Coil FORMER Annealing Shot Blast

Lubrication Forging Turning MCT

Rolling 고주파 열처리 Grinding


Forming

Basic Forming Process

CUTTING UPSET BACKWARD FORWARD

PIERCING

TRIMMING


Former5Step FORMER Formed Parts

http://ma.gnu.kr/vod/Forming/Former_KMC.avi (20s 7Mb)


ForgingFEM analysis of Clutch

FEM analysis of Helical Gear

Cold Closed Die Forging

http://ma.gnu.kr/vod/Forming/Forging_Pinion_KMC.avi Forging pinion (29s 4Mb)


Rolling

Rack Die

Up-Down of Rack

Roll Rolling Rack Rolling

http://ma.gnu.kr/vod/Forming/Rolling_KMC.avi Rack Rolling (24s, 6Mb)


Induction hardening

http://ma.gnu.kr/vod/Forming/Induction_Hardening_KMC.avi (40s 11Mb)


GrindingCenterless Clyndrical

http://ma.gnu.kr/vod/Machining/Grinding_Centerless_KMC.avi Centerless (35s 8Mb)


1 2 3 4 56

78910

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


Bevel Gear Process

Forging Turning BroachingStraight Bevel Carburizing

Pinion Gear

Forging Turning BroachingStraight Bevel GrindingCarburizing

Bevel Gear


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 Lapping

• Liquid abrasive compound is feed into the rotating gear pairs to smooth teeth surfaces.


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


InspectionITEMS SPEC.

(JIS 4)DATA

(LH/RH) RESULT

Pitch Variation 56 46/42 O.K

Pitch Error 73 68/61 O.K

AccumulativePitch Error 230 101/106 O.K

Run‐out 100 77 O.K


InspectionITEMS SPEC.

(JIS 4)DATA

(LH/RH) RESULT

Pitch Variation 62 23/27 O.K

Pitch Error 81 39/45 O.K

AccumulativePitch Error 250 157/194 O.K

Run‐out 200 165 O.K


Inspection

Standard Contact Area Contact Area Inspection


Bebel Gear Forging

Gear design

Forging simulation

Die Machining

Forging

Inspection

http://www.afdex.com


Forging simulation

<12T Bevel gear>

<20T Bevel gear>


Die machining

<12T Bevel gear> <20T Bevel gear>


Forging

Closed forging die

Press machine


Forged bevel gear

<12T Bevel gear> <20T Bevel gear>


Reference

• Gleason: www.gleason.com• 세일공업: www.seilkorea.com (정영석, 박창섭)• KMC: www.kmce.co.kr (김홍철)• AFDEX: http://www.afdex.com (전만수)

Gear Shaft.ppt [호환 모드] - Manufacturing Laboratoryma.gnu.ac.kr/course/mp/15_Gear.pdf · ·...

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