Virtual Evaluation of Gear Manufacture – To Use 3D Surface Data to Predict Performance

• The manufacturing and finishing of gears include several processes such as grinding, hobbing, shaving, honing, shot peening and phosphating. For the automotive industry it is a constant challenge to improve the durability and reduce the fuel consumption in a cost effective way by using robust processes for mass manufacturing. A better knowledge of the properties of the manufactured surfaces in gears, and especially how they interact in different combinations is an important knowledge when designing gearboxes for the future. The following paper proposes an efficient way for choosing the better manufacturing and predicting the behavior of new combinations of process parameters in the early stage of the design process based on simulations of 3D surface measurements. The simulation model uses two rough surfaces of counterpart gear teeth contacting and deforming elastically under a typically critical load during operation. Outputs from the simulations are the pressure distribution and real contact area later used for ranking the differently manufactured surfaces. Four different types of surfaces were taken from manufacturing; samples were extracted and measured on a coherence scanning interferometer. Two surface types were ground differently and two were shot-peened with different process parameters. The results show the shot-peened surfaces, especially the double shot-peened type B1, performed better than the ground ones manifested in larger real contact areas and lower/fewer pressure spikes. Based on the correlations of the 3D roughness parameters with the simulation outputs, some roughness parameters are suggested for more robust quality control.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Maskinteknik -- Tribologi (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Mechanical Engineering -- Tribology (hsv//eng)

Nyckelord

rough surfaces

white light interferometer

elastic contact

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