Fabrication of Directly Designed Gears with Symmetric and Asymmetric Teeth

摘要

When compared with the traditional gear design approach - based on pre-selected, typically standard generating rack parameters - the alternative Direct Gear Design (Ref. 1) method provides certain advantages for custom, high-performance gear drives. Among them are increased load capacity; efficiency; length-of-service; reduced size and weight; noise/vibrations; and cost. However, the manufacture of such nonstandard gears requires custom tooling and certain alterations of known gear fabrication processes. This paper presents specifics of application main methods of gear fabrication, i.e. - form and generating machining (cutting and grinding); gear forming injection molding technology; net forging; powder metal (PM) processing; die casting; and wire EDM gear prototyping. It also describes tooling profile definition, dependent upon the selected gear fabrication method. It presents the Genetic Molding Solution technique for compensation of differential warpage and shrinkage for plastic injection molding tooling - that enables enhancement of gear accuracy and shortens the process development cycle.