AGMA 95FTM11-1995 Feature-Based Definition of Bevel Gears《伞形齿轮基于功能的定义》.pdf
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1、95FTMll I Feature-B ased Definition of Bevel Gears by: Robert E. Brown, Caterpillar, Inc. TECHNICAL PAPER COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesFeature-Based Definition of Bevel Gears Robert E. Brown, Caterpillar, Inc. The statements and opin
2、ions contained herein are those of the author and should not be construed as an official action or opinion of the American Gear Manufacturers Association. Abstract Bevel gears for many appiications are subject to mcreasing levels of perfomance but with reduced cost. These factors have driven bevel g
3、ears toward sophisticated CMM control techniques. The complex shape of abevel gear tooth surface must be defned mathematically for the CMM, but the maihematical definition tends to be Wicult for direct use in gear design and manufacture. The mathematical definition may be condensed into a“featmbased
4、“ definition which is more convenient for gear design and manufacture. The featurebased definition may easily be described on the engineering drawings and subsequently toleranced to describe “fitness-for-use“ boundaries. Development and appiication of the feam it will be treated minimally. Caterpill
5、ar Gear Application Caterpillar makes a wide variety of earthmoving machinery including tractors, wheel loaders, motor graers, off highway trucks, wheel tractor scmpen, etc. Modern products of this type are continuously subject to demands for higher reliability, longer durability, improved performan
6、ce, ya lower cost. The track type tractor. for example (Figure 1). competes in the market only if within stringent cost limits, it can provide reliable service and durability levels demanded by the customer. Such machines are further subject to government noise restrictions that routinely grow in se
7、venty. This means that ail components must constantly improve, gears mcluded. Figure 1. Modern rack-type tractor 1 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesSTD-ALMA 75FTMLL-ENGL 1775 I Ob87575 OOOLi772 878 = Vhy Develop CMM Techniques? ligher de
8、mands on the bevel gears eventually led into field life and ioise problems. Enough problems were dg, along with the xpcnse of warrany. that a joim team of enginee, man- only a brief ddption of the contact p8“m was provided /lanufaaunng control was hstrated by the inevitable presence of eat treat dis
9、tonion; settings and cutter geometry were changed at the inction of the manucming forman to obtain the “correct“ contact attem. The entire process was, of course, highly subjective. ariable geometry was produced with limited understanding of the eometry and its effct on gear set stress and life. lie
10、 problems that surfaced were difficult to resolve. These appeared i the form of some parts that bad difficulties for reasons that were not lear (Figure 2). A sporadic element was present as well; sometimes good jobs drifted to “bad“ and others oscillated in and out of roblmi status. Generally, exper
11、imenting by persons with onsiderable experience was the only resolution technique and this :as not always successful. he team agreed that the best solution was to provide analytical ispection techniques for bevel gears. This was not without recedent: involute spur and helical gears were inspected wi
12、th the naiyticai equipment of the familiar variety, and had been for many - VI- inial CMM Experience he early experiments with CvM of bevel gears showed, for the fim me, that routine shop adjustments caused significant geometry hang-. Also, these showed considerable variation from heat treat ffects.
13、 From these experiments, the following conclusions were raw. 1.Analyticai measurement was mandatory to allow management of bevel gear design and manunicnUe with modem tschnology. 2.W was in hammy with the nst of CaterpiIWs c. *gopaatiorc noothercomponaitwould evcn be considered for niamifiirnm witho
14、ib the use of modan produaion technology. decisians. coiild be qlaiocd with CMM iaspeaion (Figura 3). 3.ROblcm jobs, and assuckd nianunuhinn gproceJs u that time, no commd CMM systems wem avaabie :o a decision wps reached to proceed with CMM bevel gear Ievciopment was Wiatcd for powerful FEA-based a
15、naiysis ools. uraiyticai dtvdopment at csterpillar. s-wly, :MM Application Philosophy ZMM methodology was a wry big change from the long tanding practice of contact paaem inspeaion. One could iot expect just to “drop in“ CMM inspection and have it go nto em; it was too different and no one knew exac
16、tly PARTS LEX TROUBLEMAKERS WITH PATTERS CAUSE: COXTROL ONLY: SCRAP Dorn KNOW WHY ADJumtm TROUBLE- SOME PARTS CAUSE TROUBLEMAKERS Figure 2. Parts with unclear reasons for difficulties what to expect from a CMM system in the open manufacturing environment. To devise a system that would, in fact, be e
17、ffective in the actual production mode required some planning. To meet the dual needs of design and manwg was, initially, a matter of establishing CMM application philosophy. Fim was agreement of the specific application goals. CMh4 bevel gear inspection intentions would be to: A. Enhance design acc
18、uacy for the required loads in the vehicle operation. B. Provide man- g the ability to identify the process to meet the required tooth acaracy. C. Enable process control with SPC. D. Equate cause and effect. Next was the establishment of a method approach for modem production technology requinmeats
19、2: A. Conformance to an objective standard. B. Capability based tolrranccs. c. Manufachinng * process cantrol. And then a method approach for process control: A. Evaluate the actual level of confonnance. B. Compare this actual level with the standard. C. Take corrective action if required BACK TO TH
20、E PARTS LIST: WHYTBOUBLXMAICERS? 1. PROCESS COULD BE DRIFTING - DATA HELPS MONITOR -must PROCESS VIA SPC 2. DESIGN INAPPROPRIATE FOR PROCESS -OPTIONS: a. REDESIGN *TROUBLEMAKERS Figure 3. Paro with difficulties explained by CMM inspection b. MWE TO BETTER PROCESS 2 COPYRIGHT American Gear Manufactur
21、ers Association, Inc.Licensed by Information Handling ServicesSTD-ALMA 95FTMZL-ENGL 1995 I b87575 0004773 724 I DEFINE PROCESS - ESTABLISH CAPABILITY CAPABILITY BASED TOLERANCES l I ESTABLISH TOLERANCE CLASSES FOR EACH PROCESS 8 1 I AS-HEAT i X X X X 1 TREATED i I l LNPL i IUNPL GROUND X X X X 1 1 F
22、igure 4. SPC application to specific features by tolerance class How to Display the Data? Conseasus was reached that, if CMM techniques were to be successful, there must exist a single and a clear method of bevel gear quality assessment. This was agreed to be possible oniy if analysis of bevel gear
23、inspection was broken down into components. in other words, to measure a complex 3-D tooth bevel gear surface shape and apply SPC, one must condense the measurements into srecific featurrs. A “feature“ is the general term applied to a physical part or tooth 3. Features of bevel gears or pinions are
24、bores, pinion bearing journals, splines, etc. Features of the teeh, such as profile modification, are described later in this paper. Matching of process capability and design requirements was also recognized to be important. Some process methods, such as CBN grinding, are more accurate than others.
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