• Transactions of Materials Processing
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• v.5 no.2
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• pp.105-114
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• 1996

Recently, precision forging techniques are applied to manufacture spur gears. Compared to conventional machining, they produce parts of better mechanical properties and less residual stresses with a much higher production rate. In the present investigation a rigid-plastic three dimensional finite element method was applied to analyze hot forging and cold sizing of a spur gear by closed dies. The involute curve of a tooth profile was approximated by a circle close to the curve. Results of the analyses make it possible to predict local strengths of the gear die failure and an appropriate preform for cold sizing. It was found that the preform for cold sizing. It was found that the preform for the cold sizing is the most important because it determines whether the gears especially teeth can be successfully formed.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.9
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• pp.48-53
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• 1999

In this paper, a practical method for design and machining of cycloid gear was investigated. Based on the proposed method, a systematic program was developed for automatically designing the tooth profiles of epicycloid and hypocycloid gears for the case fo one difference between the number of teeth of cycloid gear and the number coordinates of tooth profiles and pressure angles. The error analysis between cycloid curve and Biarc curve was performed to show the effective method of equidistant partitioning of cycloid curve so that efficient method of Biarc curve fitting was also proposed for the partitioned curve.

• Journal of KSNVE
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• v.10 no.1
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• pp.107-116
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• 2000

The gear whine noise caused by tooth profile, elastic deformation, machining error, wear is directly correlated with the transmission error of mating gear. It is very important to build up the synthesized countermeasure by the modeling of the excitation forces and analyzing the vibratory characteristics. The mathematical models on the elements of vehicle transmission which is composed of helical gears, bearings, shafts and cases are developed. The elements are assembled by the substructure synthesis method. The cases of transmission are modeled by ANSYS. The system model of vehicle transmission is also verified by the experiments.

• Proceedings of the KAIS Fall Conference
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• 2001.11a
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• pp.99-103
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• 2001

Though the research and the development in the field of machine tool was focused on high precision and high speed machine these days, traditional gear reduction device has been used to increase the cutting force which was transmitted from power source, motor In this study, analysis of 2 step gear reducer used in machining center spindle was carried out by using APM WinMachine which is commercial software for the analysis of machine element and system. For the analysis of this device, first of all, the analysis of power source and the transmitting of it were carried out. Then, machine elements like gear, shaft, bearing, and the forth, was analyzed in the view point of life time, static strength, stiffness, fatigue failure, etc. Consequently, we can estimate them and introduce new idea of the design modification of reduction device by this study.

• Journal of the Korean Society for Precision Engineering
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• v.28 no.7
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• pp.827-833
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• 2011

Precision forging of gears has a lot of advantages when compared to conventional gear shaping, because it allows the manufacture of gear parts without flash and consequently without the need for subsequent machining operations. In this study, the cold forging process is determined to manufacture the cold forged product for the precision clutch gear used of a commercial automobile, To do this, shape ratio of initial shape having influence the forgeability of forged product is analyzed. The optimal initial shape of clutch gear is designed using the results of DEFORM-3D and the artificial neural network (ANN). The initial shape through the detail analysis results, such as metal flow, distributions of strain can be obtained.

• Tribology and Lubricants
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• v.34 no.6
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• pp.325-331
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• 2018

Automobiles and systems requiring high gear ratios and high power densities generally use worm gears. In particular, as worm gears have a small volume and self-locking function, home appliances such as refrigerators and washers consist of worm gears. We can classify worm gears into cylindrical worms and rectangular worms. According to the AGMA standard, there are four types of cylindrical worms, ZA, ZN, ZK and ZI, depending on the machining of the worm shaft. It is preferable to use a ZI-type worm shaft, which is a combination of a worm wheel having an involute helical tooth surface and a conjugate tooth surface. However, in many cases, industries mostly use ZK, ZN, and ZA worm shafts because of the ease of processing. This paper presents numerical approaches to produce ZI and ZA worm surfaces and worm wheel. For the analysis of the transmission error of a worm gear system, this study (1) generates surface profile functions of ZI profile worm gear and worm shaft based on the common rack theory, (2) adopts the Newton-Raphson method for the analysis of the gear surface contact condition, and (3) presents and compares the corresponding transmission errors of ZI and ZA worm gears.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.11
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• pp.36-42
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• 2021

This study was conducted to analyze the effect of the gear specification and gear quality corresponding to the macro geometry on the gear transmission error. The two pairs of gears with large and small transmission errors were selected for calculation, and two pairs of gears were manufactured with different gear quality. The test gears were manufactured by two different gear specifications with ISO 5 and 8 gear quality, respectively. The transmission error measurement system consists of an input motor, reducer, encoders, gearbox, torque meter, and powder brake. To confirm the repeatability of the test results, repeatability was confirmed by performing three repetitions under all conditions, and the average value was used to compare the transmission error results. The transmission errors of the gears were analyzed and compared with the test results. When the gear quality was high, the transmission error was generally low depending on the load, and the load at which the decreasing transmission error phenomenon was completed was also lower. Even when the design transmission error according to the gear specification was different, the difference of the minimum transmission error was not large. The transmission error at the load larger than the minimum transmission error load increased to a slope similar to the slope of the analysis result.

• International Journal of Precision Engineering and Manufacturing
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• v.8 no.4
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• pp.27-32
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• 2007

Gears, crucial components in modern precision machinery for power transmission mechanisms, are required to have low contacting noise with high torque transmission, which makes the use of gear-tooth profile modifications and gear-tooth surface crowning extremely efficient and valuable. Due to the shortcomings of current techniques, such as manual rectification, mechanical modification, and numerically controlled rectification, we propose a novel electrochemical gear-tooth profile modification method based on an artificial neural network control technique. The fundamentals of electrochemical tooth-profile modifications based on real-time control and a mathematical model of the process are discussed in detail. Due to the complex and uncertain relationships among the machining parameters of electrochemical tooth-profile modification processes, we used an artificial neural network to determine the required processing electric current as the tooth-profile modification requirements were supplied. The system was implemented and a practical example was used to demonstrate that this technology is feasible and has potential applications in the production of precision machinery.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.1
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• pp.108-113
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• 2020

Pinions are generally heavy and integrated with a shaft. Thus, fabricating a pinion is a material- and machining-intensive task characterized by low productivity. Contact of the output pinion with a sliding surface or a cloud contact causes loss of power because of friction. Consequently, the output pinion undergoes considerable wear and tear at its ends, which adversely affects the overall transmission efficiency of decelerators. To improve transmission efficiency and extend gear life, an optimum output pinion design is required. To this end, in this study, an output pinion for worm gear decelerators was designed and optimized by means of product verification through prototyping and performance evaluation to improve gear life and productivity. The optimized design was validated and subjected to structural analysis.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2002.11b
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• pp.152-155
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• 2002

An industrial robot noise has various noise sources such as gears, motors, bearings, and controller fans. Among these, gears are the most dominant source for noise. The gear noise, caused by tooth profile, elastic deformation, machining error and wear, is directly correlated with the transmission error of mating gear. Due to the fact that has several axis and many gears, it is difficult to understand the characteristics of the vibration and noise of robots. In this study, some advanced analysis techniques based on digital signal processing such as power spectrum, time spectral map, RPM map, and etc., were applied for locating the dominant frequency components of the robot noises and identifying their sources. In addition, sound quality analysis was performed in order to evaluate the operator's annoyance. The noise and vibration measurements were carried out at several points during the operation of each axis considering the effect of load and posture of the robot. Eased on the results, proper countermeasures to reduce excessive noise level have been suggested considering the characteristics of sources.