Remanufacturing the Pinion: An Application of a New Design Method for Spiral Bevel Gears

Abstract

Damages of a large spiral bevel gear drive as used in heavy industry typically affect the pinion. Even if the gear still could be used, the complete pair has to be changed. This leads to long off times, high costs, and unnecessary waste. This paper applies a recent design technology for spiral bevel gears to the production of a replacement pinion for the sake of energy saving, reduction of costs and off times, and for the realization of green engineering. The process involves the following steps. First, the real tool surface of the gear is measured by a CMM. Based on the new design method, the tooth surface of the mating pinion is derived from this discrete point cloud. In order to improve the meshing performance, the resulting surface of the pinion is modified in the third step. Finally, the pinion is produced on a CNC machining center. In contrast to other approaches, none of these steps needs the parameters of the special machine tool defining the original gear pair. It is worth noting that our technology can also be profitable to gain more freedom in the design of new gear pairs.

Geometric design using undercutting and pointing conditions for a curve-face gear

“…For space gears, the researches on the undercutting and pointing phenomenon mainly focused on (1) The condition equations of tooth undercutting and tooth pointing of space gears were formulated utilizing the developed mathematical model (proposed by Litvin and Fuentes 11 and Saribay 12 ). 13,14 (2) In order to simplify the undercutting condition of the gears, some simplified formulas for, which can predict the width of the face gear as a main design parameters, were proposed. 15,16 (3) Tooth characteristics based on tooth geometry, which considered the undercutting condition, were analyzed.…”

Manufacturing method of double-helical gears using CNC machining center

“…4,5 The manufacturing methods of straight and spiral bevel gears using a CNC machining center have been proposed in order to respond such expectations. 6–10…”

“…4,5 The manufacturing methods of straight and spiral bevel gears using a CNC machining center have been proposed in order to respond such expectations. [6][7][8][9][10] In this paper, the double-helical gears are manufactured using a CNC machining center. This manufacturing method has the following advantages: (i) the tooth surfaces can be modified arbitrarily, (ii) all we have to do in gear machining is only one machine setting, (iii) the hole and blank diameter and so on except the tooth surface can be also machined, and (iv) the auxiliary apparatus, special type of tools, and special type of machine tools are not needed.…”

Applications of the Exponential Function of the Euclidean Motion Group to the Theory of Gearing

“…Most recently, the results have been applied to the remanufacturing of a pinion of a bevel gear drive; see [5] for the details.…”

“…In several subsequent papers, we will extend the theory to the kinematics, dynamics, and the geometry of gear drives. Most recently, the results have been applied to the remanufacturing of a pinion of a bevel gear drive; see [5] for the details.…”