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Gear&ShaftManufacturing SuJinKIM Gyeongsang NationalUniversity

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

Index
1. IntroductionofGear 2. GearMachining 3. Shaft&GearForming

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

Gear
Super,Helical Bevel(Straight,Spiral,Hypoid) Worm Shaft&Spline

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

GearHob
Pitch GearHob

2011 ,
Gear & Shaft Manufacturing Processes
2011 Su-Jin Kim, GNU

http://ma.gnu.kr/vod/Machining/Gear_Hob_Sim.avi Gear Hob Sim (20s)

Hobbing
Ahob(cutter)isrotatedonerevolutiontotransfereach toothprofileontoarotatinggearblank. Usedveryoftenformediumtohighsizesofproduction runs.

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

http://www.youtube.com/watch?v=TDzhSaSZrSg Gleason P90 Gear Hobber, 3 min

GearShaper
Thecutterengagesthepartontheforwardstrokeand pullsawayfromthepartonthereturnstroke.

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

Interference http://www.youtube.com/watch?v=Dd9Ekl9DPZg (60s) http://www.youtube.com/watch?v=CHQ1ZABx68o (140s)

BevelCutting

FACEMILLING HARDACcutter

NCmachining Lowproductivity

http://www.youtube.com/watch?v=8pXtSWIJ7Ac Bevel Cutting (40s) Gear & Shaft Manufacturing Processes http://www.youtube.com/watch?v=fOLaJMh6DXQ 3-axis Machining (12s)
2011 Su-Jin Kim, GNU

Gearheattreatment
Carburzing ofGears InductionHardeningofGears Ferritic Nitrocarburizing ofGears

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

http://www.youtube.com/watch?v=iI7QEI2g0lk (90s)

GearGrinding
After heattreat

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

http://www.youtube.com/watch?v=w9x7BjDhxSs Gleason Gleason 1500G Titan 10min

GearMachiningProcessofTIC
Ring Gear Flow

(/)

Pinion Gear Flow

(//)

/Test Flow (Set)


Gear & Shaft Manufacturing Processes
2011 Su-Jin Kim, GNU

TEST

Shaft &GearformingofKMC

2011 KMC
Gear & Shaft Manufacturing Processes
2011 Su-Jin Kim, GNU

Shaft &GearformingProcess
FORMER Coil FORMER Annealing Shot Blast

Lubrication

Forging

Turning

MCT

Rolling

Grinding

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

Forming

CUTTING

UPSET

BACKWARD

FORWARD

BasicFormingProcess
PIERCING

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

TRIMMING

Former
5Step FORMER FormedParts

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

http://ma.gnu.kr/vod/Forming/Former_KMC.avi (20s 7Mb)

Forging
FEM analysis of Clutch ColdClosedDieForging

FEM analysis of Helical Gear

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU

http://ma.gnu.kr/vod/Forming/Forging_Pinion_KMC.avi Forging pinion (29s 4Mb)

Rolling
RollRolling RackRolling

RackDie

Up-Down of Rack
Gear & Shaft Manufacturing Processes
2011 Su-Jin Kim, GNU

http://ma.gnu.kr/vod/Forming/Rolling_KMC.avi Rack Rolling (24s, 6Mb)

Inductionhardening

Gear & Shaft http://ma.gnu.kr/vod/Forming/Induction_Hardening_KMC.avi Manufacturing Processes


2011 Su-Jin Kim, GNU

(40s 11Mb)

Grinding
Centerless Clyndrical

Gear & Shaft Manufacturing Processes http://ma.gnu.kr/vod/Machining/Grinding_Centerless_KMC.avi


2011 Su-Jin Kim, GNU

Centerless (35s 8Mb)

Reference
Gleason:www.gleason.com :www.seilkorea.com () KMC:www.kmce.co.kr ()

Gear & Shaft Manufacturing Processes


2011 Su-Jin Kim, GNU