Professional Documents
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Bevel Gear Technology - Cylindrical Gear Technology - Measuring Centers - Drive Technology
Breakthrough
to a New Dimension
Large bevel gears can only be used to the optimum if all the steps in their pro-
Content:
- From the melt to the blank duction are interlinked from the very beginning: starting from design through
... Page 2
- Efficient gear cutting on manufacturing and on to assembly inside the gear housing. Klingelnberg’s new
large bevel gears
... Page 3 large bevel gear manufacturing unit is the core element in the large bevel gear
- Closed Loop
process chain. It is the basis for producing high-quality bevel gear sets, with
... Page 4
- Heat treatment and hard short delivery times and planning reliability for customers.
finishing
... Page 5
- Documented quality –
ready to use
... Page 5
- Closing the loop
... Page 6
COPYRIGHT KLINGELNBERG GMBH
The high power capacity of large bevel gears is in demand Input variables for the basic design are:
above all in marine drive technology, in cement and coal dust
s torque and speed of rotation
mills and in cone crushers. The groundwork for the applica-
tions-oriented design of a bevel gear based on customer’s s application
specifications takes place in the Klingelnberg KIMoS software s required safety factors for tooth root and tooth flank
package (Klingelnberg Integrated Manufacturing of Spiral
Bevel Gears), supplemented by the calculational competence Results of the basic design are:
of Klingelnberg’s in-house experts. Table 1 overviews the in- s macro-geometry (number of teeth, dimensions, …)
put variables and results for a basic design. The macrogeom-
etry is fixed, allowing for the required power transmission and s load capacity parameters according to DIN/ISO
transmission ratio, combined with the constraints imposed by and other standards
the application, such as operational load peaks, efficiency and
noise behaviour. The proof of strength calculation determines Table 1: Basic design
safety factors for root and flank damage using the methods
laid down in the standard, and com-
pares results with the specified values.
Tester contact pattern for Mt = 1902 Nm V=0.00mm, H=0.00mm, J=0.00mm
Fig. 2: The C 300 gear cutting machine performs the soft gear cutting and subsequent hard gear cutting process
Closed Loop
KIMoS
Dimensionierung
dimensioning
design
Design
COPYRIGHT KLINGELNBERG GMBH
Fig. 4: Closed-Loop
The P 300 gear measuring center is also integrated in the Heat treatment and hard finishing
closed-loop concept. The nominal data for the pitch and
topography measurements are read in from the production Heat treatment in the form of case hardening is absolutely es-
database. The actual data of the measurement are also saved sential to ensure that the material can meet the demands and
in the corresponding data record. If required, these can be stresses imposed on gear components. This is the only way to
subjected to a nominal/actual comparison using the KOMET create the graded properties profile: a hard and wear-resis-
software. After selecting suitable parameters the resulting tant surface combined with a tough core. Heat treatment is a
correction data can be transferred via the database to the core competence for bevel gear manufacturing. The capaci-
gear cutting machine. ties of the in-house hardening shop were therefore expanded
alongside construction of the new large bevel gear produc-
In practice, a separate data record is made for each custom- tion facility, and adapted to match the spectrum of manufac-
er job, to carry out the machining and measuring process cor- tured products.
rectly and avoid mix-up. This also assures full documentation
of all relevant process steps. Heat treatment necessarily entails hardening distortions,
whose minimization is a constant priority. The process chain
was therefore extended to include measurement of distortions
on the components. This step directly follows mechanical
processing, in the scope of which the reference surfaces for
gear cutting on the pinion and wheel bodies
are machined. On the basis of measured re-
sults, data records required for hardskiving are
adjusted individually. The object is to achieve
minimum flank removal, in order to assure a
maximum remaining case hardening depth on
the workpiece, allowing for the required flank
modifications. Short process times are also en-
sured.
s INSPECTION CERTIlCATE FOR THE MATERIAL
s CONTACT PATTERN PHOTOGRAPHS
s TEST CERTIlCATES
s !T THE END OF THE PATH THE CENTRAL QUALITY REQUIREMENTS FOR
a bevel gear have been fulfilled: sustainable load capacity,
minimal losses and low noise emissions.
s 4HE MANUFACTURING PROCESS HAS BEEN FULLY DOCUMENTED AND
is lean – ensuring the shortest possible process times.