Gear Production

JUN 2015

Gear Production

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6—GEAR Production Supplement F E A T U R E basic concept involves developing a robust design, partially machining the gear with some stock left in place, measuring dimensions that are automatically compared with the original design, making corrections and then completing the machining. By contrast, Rave Gears' steps involve: 1. Designing the gear 2. Planning the grinding sequence 3. Producing the gear as a near-target value 4. Measuring the result on a 3D gear analyzer and comparing with the original design 5. Calculating the variation between the design and the near-target gear 6. Making adjustments, reinstalling the gear on the grinder and continuing grinding through completion "It's basically a system that eliminates mistakes made by operator intervention," Mr. Alaniva says. "If you close the loop from design through manufacturing and inspection all the way to delivery, there is no subjectivity involved. Everything is black and white, so you're reducing variation based on hard numbers." Beginning with the development of a robust design—one that can produce a simulated contact pattern under load using Klingelnberg's Kimos/Komet and Gleason's Gage/Cage software—Mr. Alaniva makes adjustments such as contour changes before loading the resulting machining code into the grinder. "As I'm designing the gear set, the software is creating the program to actually produce the part on the grinder," he says. "It simulates a roll test that gives me transmission error, root bending, Thomas Alaniva, vice president of the gear division, has spent nearly three decades studying and improving the closed-loop manufacturing process for spiral bevel gears, including beta testing the earliest versions of the design software.

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