Session: PTG-05-01: Gear Manufacturing

Paper Number: 144101

144101 - Method for Improving Tooth Spacing and Pitch Error in Face Milled Face Gears 

The main goal of this paper is to address tooth spacing (T.S. Index Error) and pitch line runout errors encountered in face-milled face gears. By adhering to DIN 3965 gear measurement standards, which specifically encompass these errors, improvements can directly enhance gear accuracy grades. Face gears are manufactured by the face-milling method, commonly used in spiral bevel and hypoid gear cutting, with tooth surfaces derived from a universal cradle-type hypoid gear generator. Utilizing a five-axis bevel gear cutting machine, configured according to user-specified accuracy, cutter speed, and material, the study captures cutting dynamics using the TRACE function of a SIEMENS 840D controller. This data, integrated with NC codes, is analyzed using Mathematica software to inform adjustments in NC coding based on the dynamics of force within gear grooves. To optimize machining efficiency, a tri-phase feed speed protocol is implemented, which carefully increases feed speed to mitigate the initial impacts when the cutter enters the gear blank. Post-machining, gears are measured using a Klingelnberg P40 to determine tooth spacing and pitch errors, guiding further adjustments in feed speed to refine the machining process. This methodology ensures that the resulting gears meet high precision standards, demonstrating the effectiveness of adjusting feed speeds based on in-process monitoring and post-process measurements.

Presenting Author: Yi-Hui Lee National United University

Presenting Author Biography: Dr. Yi-Hui Lee is an assistant professor in the Department of Mechanical Engineering at National United University in Taiwan, specializing in bevel gear design and manufacturing.

Authors:

Yi-Hui Lee National United University
Kuan-Hung Chen National Chung Cheng University
Zhang-Hua Fong National Chung Cheng University