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antriebstechnik 11/2019

antriebstechnik 11/2019

FORSCHUNG UND

FORSCHUNG UND ENTWICKLUNG COMBINING GEAR DESIGN WITH MANUFACTURING PROCESS DECISIONS U. Kissling, U. Stolz, A. Türich Today, in many companies – mainly larger ones – design and manufacturing departments are separated and often manufacturing is provided by subcontractors. When a gearbox design is completed, and the designs of the components are transferred to manufacturing, it is usually too late for any modifications necessary for an optimal manufacturing process. The consequences are increased manufacturing costs. In this paper the introduction of manufacturing knowledge into gear design software is described. Different methods, and how manufacturing options and restrictions can be considered in the design phase, are discussed: Use of available tools such as cutters, worm grinders, etc. Checking if economic production methods such as Power Skiving and Honing are applicable. Applying known manufacturing deviations such as manufacturing twist in the gear layout process. 142 antriebstechnik 2019/11 www.antriebstechnik.de

FORSCHUNG UND ENTWICKLUNG 1 INTRODUCTION The layout of gear drives is a challenging process. Lifetime, noise, losses and other criteria must be considered. In the design process, first the overall geometry (e. g. center distance and outer dimensions of gear pairs) must be determined. Then macro geometry (e. g. module, helix angle, number of teeth, and reference profile) must be defined and optimized based on the requested design requirements. Finally, the micro geometry (e. g. profile and lead modifications) must be sized for optimum gear mesh behavior. In this complex process, a design engineer is focused on finding the best gear layout and will not often consider manufacturing constraints. It’s only after the manufacturing department gets the gear design data that the most efficient manufacturing process is evaluated and manufacturing costs are considered. Today cost-efficient gear manufacturing processes are available. But whether a process, for example Power Skiving or Honing, is possible or not depends on certain gear and pinion geometry conditions and interference contours. Often, only a small change in the macro geometry would permit the use of a more productive or less costly manufacturing process. 01 Selection of available cutters prefiltered from module and pressure angle (Symbols according ISO21771 [1]) 02 Macro-geometry variants using only available cutters Dr.-Ing. U. Kissling, Kisssoft AG, Bubikon, Switzerland; Dipl.-Ing. U. Stolz, Gleason Corporation, Ludwigsburg, Germany; Dr.-Ing. A. Türich, Gleason Corporation, Munich, Germany www.antriebstechnik.de antriebstechnik 2019/11 143

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