Analysis of gear design to take full account of process issues

GearProducts, because of their specificity, must be designed taking into account the effects of their blanks, machining, heat treatment and testing. Manufacturing-testing integration can optimize materials and processes, quantitative evaluation, help decision-making, and improve product power density. Especially for bevel gears with curved teeth, as their tools are non-standard designs, the same series is as common and serialized as possible. In addition, the gear design also focuses on the impact of its heat treatment deformation, such as not making the top of the tooth too sharp, and the root of the tooth as far as possible without leaving uncut material, try not to use too thin structure, etc.

Gear performance is also achieved with high quality and suitable materials. For gear steel, internal defects in the steel should be minimized from the strength point of view to reduce the chance of crack formation; improve the quality of the steel to enhance the resistance to crack formation and expansion. The ultimate goal is to improve the fatigue strength and life of gears. Therefore, gear product designers must understand the gear manufacturing process, otherwise they will labor without success.

In order to reduce noise, the tooth surface of the steel gear can be sulfurized or copper plated. The purpose of tooth surface sulfur penetration is to reduce the coefficient of friction of the tooth surface. Tooth surface copper plating has been used in turbine gears to improve the contact accuracy of the gear. Gear heat treatment also has an impact on the noise. For example, the gear quenching attenuation performance becomes bad, the noise will increase 3-4dB, so the strength and wear performance requirements of the gear does not need to quench. As for the influence of lubricating oil and refueling methods, it is generally believed that the noise becomes smaller with the increase of oil volume and oil viscosity, which is because lubricating oil has a damping effect and can prevent direct contact between the meshing tooth surfaces. When using oil bath lubrication, because of the different oil surface height, gear noise is also different, that is, different gear boxes have different optimal oil level.