Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

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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 & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Bevel Gear Process

Forging Turning BroachingStraight Bevel Carburizing

Pinion Gear

Forging Turning BroachingStraight Bevel GrindingCarburizing

Bevel Gear

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-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 & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Gear Lapping

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

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-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 & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Inspection

ITEMS

SPEC.

(JIS 4)

DATA (LH/RH) RESULT

Pitch Variation 56 46/42 O.K

Pitch Error 73 68/61 O.K

Accumulative Pitch Error 230 101/106 O.K

Run-out 100 77 O.K

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-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

Accumulative Pitch Error 250 157/194 O.K

Run-out 200 165 O.K

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Inspection

Standard Contact Area Contact Area Inspection

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Bebel Gear Forging

Gear designGear design

Forging simulationForging simulation

Die MachiningDie Machining

ForgingForging

InspectionInspection

http://www.afdex.com

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Forging simulation

<12T Bevel gear>

<20T Bevel gear>

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Die machining

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

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Forging

Closed forging die

Press machine

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Forged bevel gear

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

Gear & ShaftGear & ShaftManufacturing ProcessesManufacturing Processes

© 2011 © 2011 Su-Jin Kim, GNUSu-Jin Kim, GNU

Reference

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