USING SIMULATION TO CREATE THE PERFECT GEAR
Through the use of the very latest simulation techniques, we are able to improve the quality of our products continuously and we are able to develop made-to-measure gearing solutions for our customers. A key focal point concerns virtual sample testing of tools. This technology enables us right from an early stage of product development to identify potential weak areas and to design the process and the tool concepts in an optimum manner. The primary focus here is on optimum geometrical design of the gear component and its connection concept. The aim of that is to prevent undesirable shrinkage and distortion in a targeted manner in order to realize the best possible quality of component..
Fig. 1: Filling of a tooth segment Fig. 2: Filling of a double gear
Efficient gear geometry correction
To achieve the specified precision for a gear component, careful geometric precision coordination of form contours is essential. This route to a dimensionally stable part is known as gear correction and requires a structured approach. Through our in-house development of an innovative correction algorithm, we have achieved significant progress in terms of efficient gear geometry correction. This algorithm is based on a mathematically and geometrically precise method of calculation that makes it possible to perform individual gear tooth corrections to ultimate standards of precision. By applying this process to several measuring levels, we can identify deviations in the manufacturing process and can compensate for them in a targeted manner. The precise gear geometry achieved by our correction algorithm not only delivers a longer service life for transmission components. It also improves the noise characteristics and efficiency of the complete drive system. With this correction algorithm and efficient manufacturing technology at our in-house tool-building facility, we can provide precise, made-to-measure solutions for challenging applications in a diverse range of industrial sectors.
Fig. 3: Correction of gear geometry
Precise metrology
Precise metrology is an indispensable basis for achieving accurate and targeted corrections to gears and splines. As well as tactile and optical coordinate measuring systems, industrial computer tomography is also used. To reflect the requirements of component and tool geometry, we consult with our customers to identify the most appropriate kind of measuring process. Frequently, the geometric dimension of plastic gear components constitutes a major challenge for metrology. To enable us to record the geometries of very small gear components in a tactile manner, we use spherical probes with extremely small diameters in conjunction with a turntable (see Figure 4). Optical measuring systems and computer tomography are used to examine the surface characteristics of gear components although specific challenges and limits also need to be taken into account. Experienced metrologists with specialist expertise are needed to apply these techniques correctly. In addition to precise metrology, various evaluation tools perfectly suited to gear technology have a crucial role to play in analyzing, evaluating and displaying the measuring data recorded (see Figures 5 and 6). The possibilities in this area are extremely varied.
Fig. 4: On the rotary table: Tactile measurement using a spherical probe with a diameter of 0.2 mm
Fig. 5: Partial nominal-actual comparison with CT and CAD data
Fig. 6: Graphic representation of actual condition within the specified tolerance limits