Analytical gear design should fully consider process problems

gearDue to its particularity, the design of the product must consider the influence of various aspects such as its blank, machining, heat treatment and testing.Manufacturing-test integration can optimize materials and processes, quantitatively evaluate, help decision-making, and improve product power density.Especially for spiral bevel gears, because of the non-standard design of the tools, the same series should be generalized and serialized as much as possible.In addition, when designing the gear, it is also important to consider the influence of its heat treatment deformation. For example, the tip of the tooth should not be too sharp, and the root of the tooth should not leave uncut material as much as possible, and try not to use an excessively thin structure.

The realization of gear performance also requires high-quality suitable materials.For gear steel, from the perspective of strength, the internal defects of the steel should be minimized to reduce the probability of crack formation; the quality of the steel should be improved to enhance the ability to resist crack formation and propagation.Finally, the purpose of improving the fatigue strength and life of gears is achieved.Therefore, gear product designers must understand the gear manufacturing process, otherwise they will be in vain.

In order to reduce noise, sulphurizing or copper plating can be carried out on the tooth surface of the steel gear.The purpose of tooth surface vulcanization is to reduce the friction coefficient of the tooth surface.Tooth surface copper plating has been used on turbine gears to improve the contact accuracy of the gears.Gear heat treatment also has an impact on noise.For example, after the gear is quenched, the attenuation performance will deteriorate, and the noise will increase by 3-4dB, so gears with low requirements on strength and wear performance do not need to be quenched.As for the influence of lubricating oil and refueling method, it is generally believed that the noise decreases with the increase of oil volume and oil viscosity. This is because the lubricating oil has a damping effect, which can prevent the direct contact of the meshing tooth surfaces.When using oil bath lubrication, due to the different oil level, the gear noise is also different, that is, different gear boxes have different optimal oil levels.