gear shaft.ppt [호환 모드] - manufacturing laboratoryma.gnu.ac.kr/course/mp/15_gear.pdf · ·...
TRANSCRIPT
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Manufacturing Process
Gear & Shaft Manufacturing
Associate Professor Su-Jin Kim
School of Mechanical EngineeringGyeongsang National University
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
[모듈 공급업체]현대모비스한라공조
Powertrain Module
[생산업체]현대위아S&T중공업
에스엘경창산업
Transmission
[생산업체]현대모비스모토닉, 지코
화신, S&T대우한국프랜지SJM, 현대EP
Engine
Powertrain Module of Automobile
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Index
1. Introduction of Gear2. Gear Machining3. Shaft & Gear Forming4. Bevel Cutting5. Bevel Forging
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Gear
• Super, Helical• Bevel(Straight, Spiral, Hypoid)• Worm• Shaft & Spline
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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)
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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 & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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 & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Gear heat treatment
http://www.youtube.com/watch?v=iI7QEI2g0lk (90s)
• Carburzing of Gears• Induction Hardening of Gears• Ferritic Nitrocarburizing of Gears
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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 & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Shaft & Gear forming of KMC
© 2011 김홍철 KMC
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Shaft & Gear forming ProcessFORMER Coil FORMER Annealing Shot Blast
Lubrication Forging Turning MCT
Rolling 고주파 열처리 Grinding
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Forming
Basic Forming Process
CUTTING UPSET BACKWARD FORWARD
PIERCING
TRIMMING
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Former5Step FORMER Formed Parts
http://ma.gnu.kr/vod/Forming/Former_KMC.avi (20s 7Mb)
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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)
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Rolling
Rack Die
Up-Down of Rack
Roll Rolling Rack Rolling
http://ma.gnu.kr/vod/Forming/Rolling_KMC.avi Rack Rolling (24s, 6Mb)
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Induction hardening
http://ma.gnu.kr/vod/Forming/Induction_Hardening_KMC.avi (40s 11Mb)
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
GrindingCenterless Clyndrical
http://ma.gnu.kr/vod/Machining/Grinding_Centerless_KMC.avi Centerless (35s 8Mb)
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Bevel Gear Process
Forging Turning BroachingStraight Bevel Carburizing
Pinion Gear
Forging Turning BroachingStraight Bevel GrindingCarburizing
Bevel Gear
Gear & ShaftManufacturing Processes© 2011 Su-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 & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Gear Lapping
• Liquid abrasive compound is feed into the rotating gear pairs to smooth teeth surfaces.
Gear & ShaftManufacturing Processes© 2011 Su-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 & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
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
Gear & ShaftManufacturing Processes© 2011 Su-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
AccumulativePitch Error 250 157/194 O.K
Run‐out 200 165 O.K
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Inspection
Standard Contact Area Contact Area Inspection
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Bebel Gear Forging
Gear design
Forging simulation
Die Machining
Forging
Inspection
http://www.afdex.com
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Forging simulation
<12T Bevel gear>
<20T Bevel gear>
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Die machining
<12T Bevel gear> <20T Bevel gear>
Gear & ShaftManufacturing Processes© 2011 Su-Jin Kim, GNU
Forged bevel gear
<12T Bevel gear> <20T Bevel gear>