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851572
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851512
Production Measurement Technique for
In=Process Control of Spiral Bevel Gearing
A. J. Lemanski
Sikorsky Aircraft Div.
United Technology Corp.
1985 International Off-Highway & Powerplant
Congress & Exposition
MECCA, Milwaul<ee, Wisconsin
September 9-12,1985
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ISSNOI48 7191
Copyright 1985Societyof Automotive Engineers,lnc.
This paper is subject to revision. Statements and opinions ad"
vam'cd in papers or discussion arc the aethor's and arc his
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by SAt for uniform styling and format. Discussion will be
printed \vith thc paper if it is published in SAl Transactions.
ror permission to publish this paper in full or in part, contact
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Persons wishinl;! to submit papers to be considered for pre-
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851572
Production Measurement Technique for
In-Process Control of Spiral Bevel Gearing
A. J. Lemanski
Sikorsky Aircraft Div.
United Technology Corp.
Abstract
An advanced measuring technique for in-process inspection of spiral bevel
gearing utilizing a computer controlled multi-axis precision coordinate mea-
suring machine has been developed at Sikorsky Aircraft under sponsorship of the
U.S. Army Aviation Systems Command, St. Louis, ~ l out of AVSCON Propulsion
Laboratory, Cleveland, Ohio.
This paper describes both the current state-of-the-art inspection tech-
nique and an advanced production technique for the in-process inspection and
manufacture of high quality spiral bevel gearing. The inspection method
currently used for the control of spur and helical tooth profiles is not
feasible for spiral bevel gears because the tooth shape and thickness varies
over its face width instead of being constant as in the case of spur and
helical gears. Spiral bevel gears are currently inspected on Gleason test
machines which provide rotating check simulating no-load operation under
specified gearbox mounting conditions. Tooth contact patterns are observed by
painting the teeth with a marking compound and running the gear with its mating
master control gear in a Gleason tester with a light brake load. The gear
typically exhibits a localized composite tooth bearing contact pattern \",hich,
ideally, should spread out under the operating load, filling the working area
of the tooth. The inspection task is a subjective one to ascertain an accept-
able full load pattern from a localized composite pattern. The machine oper-
ators task is even more difficult because he must make a judgment to change the
machine settings in order to correct an undesirable feature in the test pat-
tern.
The advance production measuring technique involves mapping of spiral
teeth over their entire working surfaces using a precision coordinate measuring
machine and quantitatively comparing surface normals with nominal master gear
values or \",ith theoretical values at some 45 grid points. In addition, this
technique features a means for rapidly calculating corrective grinding or
cutting machine setting changes for controlling the tooth profile geometry
within specified tolerance requirements.
Both the gear designer and the gear manufacturing Engineer will have more
options in the analysis and manufacture of bevel gearing due to the positive
control of the tooth profile geometry and related gear dimensions as made
possible by the advanced technique.
Introduction
The inspection of tooth profiles that is commonly performed on spur and
helical gears is not feasible for spiral bevel gears because the tooth shape
and thickness varies over its face width instead of being constant as in the
case of spur and helical gears. Spiral Bevel Gears are currently inspected on
Gleason test machines which provide a rotating check simulating no-load opera-
tion under actual gearbox mounting conditions. Tooth contact patterns under
these conditions can be observed by painting the teeth with a marking compound
and running the gear with its mating master control gear for a few seconds in
the Gleason tester with a light brake load. The gears typically exhibit a
localized composite tooth bearing contact pattern which, ideally, should spread
out under the operating load) fill ing the working area of the tooth. The
inspection task is a subjective one to ascertain an acceptable full load
pattern from a localized composite pattern. The machine operators task is even
01487191/85/09091572$02.50
Copyright 1985 Society of Automotive Engineers, Inc.
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2
more difficult because he must. make a judgment to change the machine settings
in order to correct an undesirable feat lire in the test pattern. This
faeturing process for spiral bevel gears is more time consuming and costly ,,,,hen
compared to the spur and helical process of control.
Experience has shown that highly londed aircraft spiral bevel gears can
develop a tooth scoring failure during production acceptance tests of trans-
missions even though the tooth contact pattern loJas within specification limits
as determined by the present method of control.
The current bevel gear met.hod requires the use of master control gears
which are manufactured by the same process used for the production gears.
Also, duplicate masters are required for second and third source production and
additional levels of master gear control. From a metrology point of view, it
is most desirable to manufacture the control master gears to a higher level of
accuracy which is currently not possible by the present method.
State Of The Art Of Spiral Bevel
Gear
Spiral bevel gears are currently inspected on a Gleason
test machine, shown in Figure 1, \l"hich provides a rotating test of the gear
its control master gear simulating no-load operation under actual gearbox
mounting conditions. Tooth contact patterns under these rotating conditions
are observed by painting the teeth a marking compound and running the
gears with their mating master control gcars for a few seconds in the gear
tester under a light brake load. Because of the compound curvatures inherent
in the spiral bevel gear tooth form and the profile modifications designed into
the tooth geometry, these gears typically exhibit a localized composite tooth
bearing pattern (Figure 2) v:hich; ideally, should spread out under full load,
filling the twrking area of the tooth with some easing off at the end areas of
contact. The size, shape, and pOSition of this tooth bearing pattern is a
gross indication of the tooth topology both up and dotm the tooth profile and
lengthwise along the tooth face.
FIGURE 1 GLEASON ROLLING TEST MACHINE
851572
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851572
PATTERN TAPE RECORD
!.STER GEAR PH/l011
WnRAl BEARlNG - DRIVE
9f'bn
wnRAL BEARHlG COAST
--
AM
..,..::
--
FIGURE 2 SPIRAL BEVEL GEAR TOOTH CONTACT PATTERN
The goal of the design and dC\'c]oplIIent phase of spiral bevel gear
manufacture is to obtain a localized test machine pattern of a size, shape, and
location that will produce the desired full load pattern in the gearbox. The
goal of the gear production phase consists of dupl iC<1ting the desired tooth
shape during a production run and from Dill' prodllCl iOIl run to another.
This current method of manufacturin
h
prim,lry drive spiral bevel gears
requires an experienced and qual ificd orgiln iZ:Jl ion. I t is often expressed that
the development of a spiral bevel gCill- of all art. than a science. This
expression is based on the requirement for ski bevel gear machine operators
who must use their background expcricllcp to pV.lluate the position, shape and
contour of the gear tooth pattern prouucl'd by the rolling test in the test
machine. The machine operator's is relied upon to determine what
machine setting or combination of is best used to correct an un-
desirable featured in the test pattern.
The Gleason gear grinding is ;j culmin3tion of motions and tool
paths that generate the bevel gear tooth !orm inte i1 continually varying
non-involute curve. Basically, thr, G11\<'15011 gl'ilr grinder, shown in Figure 3,
has a cradle that supports the formed grillding l.\'hecl shm.;n and has a radial
oscillating motion while the ill ilnd out of the gear tooth space.
FIGURE 3 GLEASON HYPOID GEAR GRINDER
3
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4
This cradle motion is controlled by <l genl'raL illg cam that can be adjusted
through the cradle angle setting to modify Lill' r,\tio of motion at one end of
the oscillating arc in relation to til(' othl'!" r-nd. 1'11{' gear to be ground is
mounted on a work holding fixLUrf' Cl'lll,:red to the work spindle that
is in constant rotational motiOIl ill iJ cOllt.l"ollld Tatio La the cradle. The
grinding wheel is mounted concentric l(, till' crildll' axis (Figure 4) in a fixed
relative position to the cradle center depl'lldpllt upon the wheel radius, the
spiral angle, and hand of spiral. Th,< grindillg 1,..heel. in effect, acts as a
single tooth of an imaginary general illg gPilr TIll' t.;hcel is dressed automati-
cally at prescribed stages in thf' griudillg :-'1'lj1H'IICI' to muinr.ain surface finish
and profile accuracy.
_Cradle 1 - I,;radle
Center I
. . .
_.00038
.
I-
..0 .
,(
),
--
,;
,
.-
.01
-
\
.
.........--
Gleason PnoFtlE IEASl$EIEIH f'lfllOtl .,
.....:"''''"
G MET "... ",,,..
'0-
f. t. ...
conneCteD
MACHlIIE SETTINGS
EtC MIO. 0
CR/l.DLE /l.NG. 0
SllDlIIG DJISE 0
I\OOT /l.IIG. 0
pnESSVRE /l.NO. 0<> II'
DEVIATIONS CONVERTED INTO CORRECTNE MACHIlE SETTINGS
FIGURE 27 RESULTS OF 1st CORRECTIVE GRIND
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18
851572
(lM(TCOIlArCTED
MflClmlE Sntl'lGS
ECCMIG 0
Cl1l1DU ANa 0
StlDmG !IASE 0
floor MiG 0
rnrswl!E IINI; fI' 2'
,"""..... .,.. ...'l
PIIOFILE "USU1JEIIT PlIuml
G-MET
....1_"'''''''''
Gleason
mrr-="
/ / ,/ ,/ .v
""",/f/ ///
--,J;; //7/
-.".m - - ,/ /
,I\c- -="
L\ \
DEVIATIONS CONVERTED INTO CORRECTIVE MACHINE SETTlNGS
FIGURE 28 RESULTS OF 2nd CORRECTIVE GRIND
In all four of the above CilSP:-.. thl' be\'vl pinioll tooth profile geometry
wc:s restored to within acceptabl(' limits ill l\o.'o rlgrinds using only first order
changes. This demonstrated thul the corn'clivp procedure was effective
in correcting an out -of -tolcrancp. looth pro f i 1(' tiu ring thl' production process.
this technique can eliminate the for ;1 fill;!1
ACCEPTA\CE n:ST l'ROCElll"RE I ATI')
Three sets of UH-60 main gcarho::-: spirill hewl "'ere manufactured by
the improved technique for dynnmic load test ing to production acceptance
test procedure (ATP). For the ATP po\.>'c.r SPl' Figur 29.
MIN JSS I 0\ ACCI:I'TA\CI: TEST
PROCI:IIl"RES (ATPI
POIIER TEST
PO\,ER (SIlI'I Dl'R;\TION
L/Il INPUT
TIO
400 400
.,
5
-,
700 700 0) 15
1000 1000 170 10
1250 1250 2:10 5
700 700 6; 5
1400 1400 200 5
FIGURE 29
Results of the three tests conducted lo llw ATP power spectrum are as
follows: (See Figure 30):
Test 1 -
Test 2
Test 3
Visual inspection indiC<1tcd flO di::>lress.
Visual inspection indici1tcd n modcnltt profile scoring condition
on both pinion and genr.
Visual inspection indicated n moderate profile scoring and wear
condition on both pinion and gnar.
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851572
TEST 1
ATP - DYt\II:'11 C LOA!) TI:ST KESlI.TS
Gear and Pinion Ground lo Produclioll
19
Pinion Condition After Test Gear CO!l(Ii l i 011- ,\ It {'l' Tes l
TEST 2
---
Pinion Ground to il Prr's,.,lJrp Aug!" Error of 07', Resulting in a
+.0004" Profi!e IlI'\'jilLiOJi.
Pinion Condition After Test Gear Condilioll Atllr Tpsl
TEST 3 Pinion Ground Lo d I.PII;.;lh l\is{' (;ur\'aturl' Error of
Wheel Diameter and ,02(j 111::11"'" S id"
Resulting in il +.0007" Profi!,' iJp\'jaLioll.
.040 Inches on
Radial Change
Pinion Condition After Test
Geilr Cond i l i Oil ,\[ l" r Tps l
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20
Conclusions
Application of the improved inspection method for spiral bevel gears)
described herein, can provide the following benefits:
1. Permits quantitative evaluation of tooth profiles.
2. A substantial reduction in Manufacturing and inspection manhours and
associated cost.
3. Measurement of all blank dimensions and tooth elements, including
tooth spacing and index variation; in one set up.
4. Permits measuring entire tooth surface rather than the localized
contact area measured by the current technique.
5. Eliminates the need for, and costs associated with, metallic master
control gears and working master gears used for production quality
control. Also eliminates the inherent variability of master gears.
6. Produces both digital and graphical records of the tooth geometry.
7. Automatically calculates the most optimum grinding machine corrective
settings necessary to correct profiles tdth deviations outside the
established tolerance range.
References
1. Lemanski, A.J., and Frint. H.K., Automatic Inspection and Precision
Grinding of Spiral Bevel Gears, AHS Paper No. A-84-40-34-5000, presented
at the 40th Annual Forum of the American Helicopter Society, Arlington,
Virginia, May 16-18, 1984.
2. Lemanski, A.J., Frint, H.K., and Glasow. ~ Manufacturing Perspective in
The Design of Bevel Gearing, AGARD-CP-369. Paper No. 15, Gears and Power
Transmission Systems for Helicopters and Turboprops. Presented At The
Propulsion and Energetics Panel 64th Symposium. Helo in Lisbon. Portugal,
8-12 October 1984.
851572
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This paper subject to revision. Statements and opinions ad-
vanced in papers or discussion arc the author's and arc his
responsibility, not SAE's; however, the paper has been edited
by SAl': for uniform styling and formal. Discussion will be
printed with the paper if it is published in SAE Transactions.
For permission to publish Ihis paper in ful.l or in part, contact
the SAE Publ.ications Division.
Persons wishing to submit papers to be considered for pre-
sentation or publ.ication through S.-\E should send the manu-
script or a 300 word abstract of a proposed manuscript to:
Secretary. Enbtineering Activity Board, SA.
Printed in U.S.A.
Downloaded from SAE International by University of Michigan, Wednesday, October 29, 2014