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Gear Manufacturing & Inspection: Methods, Practices, Application & Interpretation for the Design Engineer

Course Outline A. Gear Manufacturing

A.1. Summary of Gear Manufacturing Process A.1.1. Generating A.1.2. Forming A.1.3. Non-controlled A.2. Generating Processes A.2.1.1. Hobbing A.2.1.1.1. Rack Tooth Form A.2.1.1.2. Gang Hobbing A.2.1.1.3. Special Hobs for Internal Gears A.2.1.1.4. Hobbing Spiral Bevel Gears A.2.2. Shaping A.2.2.1. Stroke A.2.2.2. Continuous A.2.2.3. Wafer Cutters A.2.3. Gear Planning A.2.3.1. Rack Cutters A.2.3.2. CBN Hard Cutting A.2.3.3. Backer Bars A.2.4. Face Milling A.2.5. Skiving A.2.6. Generating Grinding A.2.7. Roll Forming A.2.8. Disk Milling A.2.9. Hobbing A.2.10. Shaping ­ Pinion Shaped Tool A.2.11. Disk Cutter A.2.12. Shaping A.2.13. Continuous Rack Shaping A.2.14. Special Purpose Machines A.2.15. Face Milling Spiral Bevel Gears A.2.16. Face Hobbing Spiral Bevel Gears A.2.17. Skiving With Carbide Hob A.2.18. Hard Finishing Bevel Gears A.2.19. Generating Grinding Parallel Axis Gears A.2.19.1. Conical Wheel A.2.19.2. Saucer Shaped Wheel A.2.19.3. Threaded Wheel A.2.20. Generating Grinding Bevel Gears A.2.21. Bevel Gear Planning A.2.22. Bevel Gear Planning Generator A.2.23. Two Tool Generator ­ Straight Bevel Gears A.2.24. Roll Forming A.2.24.1. Parallel Axis Gears A.2.24.2. Worm Gears A.2.25. Roll Finishing A.2.26. Generating Straight Bevel Gears With Disk Tools

A.2.26.1. Cutting A.2.26.2. Grinding A.3. Forming Processes A.3.1. Form Milling A.3.2. Slotting A.3.3. Gashing A.3.4. Form Grinding A.3.4.1. Aluminum Oxide A.3.4.2. CBN A.3.5. Broaching A.3.6. Shearing A.3.7. Forging A.3.7.1. Net Shape A.3.7.2. Near Net Shape A.3.7.3. Powder Processes A.3.7.4. Die Casting A.3.7.5. Injection Molding A.3.7.6. Extrusion A.3.7.7. Stamping A.3.7.8. Flame Cutting A.3.7.9. Electrical Discharge Machining A.3.7.10. Photo Chemical Machining A.4. Non-Controlled A.4.1. Lapping A.4.2. Burnishing A.4.3. Honing A.4.4. Hard Honing A.4.5. Soft Honing A.4.6. Polish Honing A.4.7. Shaving A.4.8. Super Finishing

B. Inspection

B.1. Purposes B.1.1. Accept/Reject B.1.2. Determine Acceptability For Application B.2. Types of Inspection B.3. Geometric B.3.1. Chart Identification & Part Orientation B.3.2. Use and Interpretation of AGMA Quality Numbers B.3.3. Elemental B.3.3.1. Involute Profile B.3.3.2. Lead B.3.3.3. Tooth Spacing B.3.3.4. Runout B.3.3.5. Tooth Thickness B.3.3.6. Surface Finish B.3.3.7. Apex Alignment (Double Helical Gears) B.3.3.8. Specifying Tooth Geometry Modifications B.3.3.8.1. Profile Modifications B.3.3.8.2. Engineered Crowned Lead Corrections B.3.4. Composite B.3.4.1. Contact Patterns & Backlash B.3.4.1.1. In Situ

B.3.4.1.2. In Roll Stands B.3.4.1.3. Bevel and Hypoid Gear V, H & Y (E, P &G) B.3.4.1.4. Contact Pattern & Load Intensity B.3.4.2. Double Flank Composite ("Red Liner") B.3.4.3. Single Flank Composite (Transmission Error) B.4. Noncontacting Methods B.5. Nondestructive B.5.1. Ultrasonic B.5.1.1. Equipment B.5.1.2. Techniques & Interpretation B.5.2. Acid Etch B.5.2.1. Swab Etch for Larger Parts B.5.2.2. Bath Etch for Smaller Parts B.5.3. Barkhausen Effect B.5.3.1. Theory and Application B.5.3.2. Applicability to Gears B.5.4. Magnetic Particle B.6. Destructive B.6.1. Heat Treatment Test Coupons B.6.2. Gear Specimens

C. CMM vs. Conventional Measuring Tools D. Establishing Requirements E. Summary & Questions and Answers

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