Abstract

The paper is targeting on the finishing of precision gears for low-noise/noiseless transmission for cars and light trucks. Transmission error is the predominant cause of gear noise. The application of a topologically modified pinion results in reduction of transmission error up to two times. The required modification of the pinion tooth surface is provided on a plunge shaving operation with application of a shaving cutter of an appropriate design. A novel approach for computation of parameters of a form grinding wheel for grinding of the shaving cutter for plunge shaving of a precision involute pinion with topologically modified tooth surface is reported in the paper. The developed approach for computation of parameters of the form grinding wheel is focused on application of the shaving cutter grinder with a lack of CNC articulation. The problem under consideration is solved using the DG/K-based approach of part surface machining earlier developed by the author. (The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and in kinematics of multi-parametric motion of a rigid body in E3 space (See Radzevich, S.P., Sculptured Surface Machining on Multi-Axis CNC Machine. Monograph, 1991, Vishcha Shkola Publishers, Kiev (in Russian). See also Radzevich, S.P., 2001, Fundamentals of Surface Machining. Monograph, Rastan, Kiev (in Russian).) An analytical solution to the problem is discussed in the paper. The solution has been used for developing software for the Mitsubishi ZA30CNC shaving cutter grinder for the needs of the automotive industry. Computer simulation reveals high accuracy of the ground shaving cutter.

1.
Dudley
,
D. W.
, 1991,
Gear Handbook. The Design, Manufacture, and Applications of Gears
,
2nd ed.
,
McGraw-Hill
, New York.
2.
Modern Methods of Gear Manufacture
, 4th ed., 1972, National Broach & Machine Div., Lear Siegler, Inc., p.
159
.
3.
Townsend
,
D. P.
, 1992,
Dudley’s Gear Handbook: The Design, Manufacture, and Application of Gears
, 2nd ed.,
McGraw-Hill, Inc.
, New York.
4.
Bianco
,
G.
, 2000,
Gear Shaving
,
Jiuge
, Beijing.
5.
Radzevich
,
S. P.
, 2003, “
Design a Shaving Cutter for Plunge Shaving a Topologically Modified Involute Pinion
,”
ASME J. Mech. Des.
1050-0472,
125
, pp.
632
639
.
6.
Olivier
,
T.
, 1842,
Theorie Geometrique des Engrenages
, Paris.
7.
Radzevich
,
S. P.
, 2001,
Fundamentals of Surface Machining. Monograph
, Kiev, Rastan (in Russian)
8.
Radzevich
,
S. P.
, 1987,
A Method of Designing of the Optimal Cutting Tool for Machining a Given Sculptured Surface on Multi-Axis CNC Machine
, Patent No: 4242296/08 (USSR), filed: 31.03.1987г.
9.
Shishkov
,
V. A.
, 1951,
Kinematical Approach of Enveloping Surfaces Generating for Part Surfaces Machining
, Mashgiz, Moscow.
10.
Radzevich
,
S. P.
, 2004, “
Finishing Precise Gears for Low Noise/Noiseless Car Transmission
,” in
Proceedings of the 1st Annual Manufacturing Technology Summit
, August 10–11,
University of Michigan/Dearborn Fairlane Center
, SME.
11.
Radzevich
,
S. P.
,
Palaguta
,
V. A.
, and
Goodman
,
E. D.
, 1998,
Geometry of Helical Gear and Tool Surfaces for Plunge Shaving of Involute Gears
, Final Data Report, Michigan State University/Chrysler Corporation.
12.
Radzevich
,
S. P.
, 1991,
Sculptured Surface Machining on Multi-Axis CNC Machine. Monograph
,
Vishcha Shkola Publishing House
, Kiev (in Russian) (The monograph is available in The Library of Congress).
13.
Radzevich
,
S. P.
, 2002, “
Conditions of Proper Sculptured Surface Machining
,”
Comput.-Aided Des.
0010-4485,
34
(
10
), pp.
727
740
.
14.
Mortenson
,
M. E.
, 1985,
Geometric Modeling
,
John Wiley & Sons
, New York.
15.
Buckingham
,
E.
, 1963,
Analytical Mechanics of Gears
,
Dover Publications, Inc.
, New York.
16.
Radzevich
,
S. P.
, 2004, “
Modified Shaving Cutters for Low Noise
,”
Gear Technol.
0743-6858, Jan./Feb., p.
26
.
You do not currently have access to this content.